Method and apparatus for casing flexible containers

Apparatus and method is disclosed for loading a plurality of bales or containers containing pouches filled with a liquid such as milk into a rectangular open-top case. An empty case is located on the apparatus and a rotatable divider is positioned on the case to create suitable bale-receiving compartments. The bales are fed to a diverter which moves each bale to a position overlying an empty compartment so that the bale falls into the compartment. The divider then rotates to rotate the case to bring another empty compartment into registry with the diverter. This repeats until the case is full, at which time the divider is withdrawn vertically from the case and the full case is fed to an outlet conveyor. An empty case is brought to a position below the raised divider, the divider is lowered into the empty case and the filling process is repeated. The case has been filled symmetrically and is easy to handle thereafter.

The present invention relates to the packaging of flexible containers in 
general and in particular to the packaging of pouches of milk contained in 
an overbag into rectangular cases. 
BACKGROUND OF THE INVENTION 
Canadian Pat. No. 1,008,040 issued on Apr. 5, 1977 describes apparatus for 
packaging a plurality of pouches of a liquid such as milk in an overbag. 
The pouches usually contain a quart of milk each and subsequent to the 
overbagging operation the overbags are sealed and are fed to a loading 
station. At the loading station the overbags are manually placed in 
cartons or crates for transport to the dairy. 
Recently dairies have invested heavily in rectangular plastic cases for the 
transport of milk in one, two or three quart cartons. The cases are sized 
so that a fixed quantity of the milk cartons can be located therein with 
little or no lost space. The cases are stackable and easily handled both 
in the dairy and in the retail outlet. With the increase in popularity of 
the overbag and pouch packaging of milk it becomes desirable to utilize 
these cases for the packaging of such overbags. It becomes even more 
desirable to depart from the practice of manually loading the overbags in 
their transport cartons in view of the extremely high speeds of the 
pouching equipment (approaching 100 pouches per minute). 
SUMMARY OF THE INVENTION 
The present invention fulfils this need by providing an automatic 
mechanical device which will load four overbags herein designated as 
"bales", each containing three one-quart pouches in the standard dairy 
case now in use. The bales are symmetrically loaded in the case so that 
the case is fully balanced and hence easy to handle. There will be no 
damage to the bales, or their contents, always a consideration when manual 
methods are used, and the speed of the loading operation will be such as 
to keep up with the overbagging equipment. 
In its basic form the present invention contemplates a method of loading a 
plurality of flexible containers symmetrically in a generally rectangular 
open-top case comprising the steps of: a) locating removable divider means 
in said case, said divider means forming a plurality of symmetrically 
positioned compartments in said case; b) loading said compartments with 
said containers, with one container per compartment; and, c) removing said 
divider means from said case, leaving said containers in position in the 
case. 
The method of the present invention may be carried out by a loading device 
for locating a plurality of flexible containers symmetrically in a 
generally rectangular open-top case comprising: a framework; means for 
locating an empty case in the framework; divider means positionable in the 
case, dividing the case into a plurality of compartments each sized to 
receive one of the containers; conveyor means for feeding containers into 
said framework; diverter means for moving a container from the conveyor 
means to a position overlying an empty compartment so that the container 
will fall into the empty compartment; means for rotating the divider means 
and the case to index the compartments; means for removing the divider 
means from the case when all compartments are full; and, means for 
removing the full case from the framework. 
In one embodiment the main components are connected to an open framework 
with the containers or bales travelling from the overbagger along a 
conveyor which terminates in the framework at an elevation corresponding 
essentially to the top edge of the sides of the dairy case. The case is 
located on a flat surface within the framework adjacent the inlet conveyor 
and with one side parallel to the conveyor. A divider assembly is 
connected to the framework so that the divider itself can be raised or 
lowered with respect to the interior of the case. The divider includes a 
central vertical hub with a plurality of vanes extending therefrom, sized 
so that when the divider is within the case an adjacent pair of vanes will 
form a compartment with two sides of the case, the compartment being open 
at the top. Thus if the hub has four vanes there will be four compartments 
formed in the case, the compartments being symmetrical with respect to the 
hub. The vanes extend out from the hub a distance sufficient that their 
outer edges are in very close proximity to the inside walls of the case. A 
diverter is positioned at the end of the inlet conveyor to receive a bale 
brought from the overbagger. The diverter can move the bale to a position 
overlying an empty compartment so that the bale will fall into the 
compartment when the diverter is aligned with the compartment. The return 
of the diverter to its original position causes the operation of an 
indexing mechanism which rotates the divider, and in turn the case, so 
that another empty compartment is brought into a position to receive a 
bale. Once the divider has rotated a predetermined number of times the 
compartments will all be full and the divider will be removed upwardly 
from the case, leaving the case with the bales therein. As the divider 
vanes depart the flexible nature of the bales will permit each bale to 
expand into contact with two adjacent bales and the frictional contact 
established thereby will tend to reduce any movement of the bales within 
the case. Once the divider is clear of the case the full case is removed 
from the framework and a new empty case takes its place.

DETAILED DESCRIPTION OF THE DRAWINGS 
FIG. 1 shows a perspective view of the apparatus of the present invention 
wherein it is seen that there is a main framework 10 which includes a 
first, generally L-shaped portion 12, in plan, and a second side portion 
14. Thus portion 12 includes horizontal side members 16, 18, 20, 22, 24 
and upright members 26, 28 while portion 14 includes horizontal side 
members 30, 34 and upright members 36, 38, 40 40a. Also included as part 
of the framework is an operating platform 42 forming a base for the open 
area of the apparatus, an inlet conveyor 44 and an outlet conveyor 46. The 
inlet conveyor 44 brings in an empty case 48, between frame members 22 and 
24 and outlet conveyor 46 will take a full case away from platform 42. 
Drive for the cases is provided by a drive cylinder 50 which is mounted 
horizontally between frame members 30 and 34. The mounting means is 
conventional and has been omitted for the sake of clarity. Also mounted 
between frame members 30 and 34, and anchored to upright members 36 and 38 
is a pair of guide rods 52. In the embodiment according to FIG. 1 cylinder 
50 is positioned between the guide rods 52. 
The piston rod 54 of cylinder 50 is connected at its free end to a lug 56 
affixed to a generally horizontal connecting bar 58. At each end of bar 58 
there is an upright mounting bar 60 which carries a pair of journal 
bearing blocks 62, journaled to the guide rods 52. Each mounting bar 
carries a generally upright cylinder 66a or 66b with its piston rod 
pointing downwardly and connected at its free end to the bell crank 
portion 64 of a corresponding push bar 68a or 68b. The bell crank portions 
64 are each journaled between a pair of brackets 70 projecting outwardly 
from the bottom portion of the respective mounting bar 60 (see FIG. 2). It 
should be pointed out that platform 42 is provided with a trough portion 
43 along one side thereof, the trough providing clearance for bell crank 
portions 64 during reciprocation of the push bar assembly. 
Mounted in the framework, as to frame members 22 and 30 is an inlet 
conveyor 74, the drive for which is not shown. Mounted to the framework 
above the inlet conveyor 74 is a diverter assembly 76 which includes a 
generally U-shaped diverter 78, a power drive means such as cylinder 80 
(FIG. 2) and a switch 82 mounted within diverter 78. The cylinder 80 and 
diverter 78 are mounted so that operation of the cylinder can move the 
diverter from a position overlying conveyor 74 to a position overlying the 
operating platform 42. Diverter 74 is open both top and bottom and its 
open side faces upstream along conveyor 74. 
Also mounted in the framework 10 is the divider assembly 84. The assembly 
includes a divider 86 having a central, generally rectangular hub 88 with 
a coaxial shaft 90 keyed thereto and extending vertically therefrom. Each 
vertical side of hub 88 has a vane 92 which appears as an extension of the 
hub side, the vanes being mutually perpendicular to each other. Each vane 
is perforated by a plurality of through holes 94, as is diverter 74. It 
should be pointed out that the length of each vane 92 is such that with 
the entire divider located within a case and the vanes being essentially 
parallel to the case sides the outer edge of each vane will almost touch 
the adjacent side of the case. 
Connected to the shaft 90 is a indexing mechanism or drive assembly 96 
which will impart rotational movement to the divider 86. Assembly 96 
includes a housing 98 having top and bottom plates 100 and 102 
respectively. (FIGS. 3, 3a, 3b, 3e.) The housing encompasses shaft 90 as 
by stepped bearing 104, there being one bearing associated with each of 
the top and bottom plates. Each bearing has a central bore 105 sized to 
receive shaft 90 therethrough for rotation therein. Top plate 100 is also 
provided with two longitudinally directed slots 106, 108, one being 
approximately centered therein, the other being offset to one side. 
Within housing 98 is a drive cylinder 110 anchored thereto as by a bracket 
(not shown) and having its piston rod 112 directed towards shaft 90. The 
free end of piston rod 112 is threaded into a block 114 which is slidably 
received in the housing 98. Block 114 is shown in greater detail in FIG. 4 
wherein it is seen to include a main section 116 to which rod 112 is 
connected as by threaded hole 118, and a pair of plates 120 each carrying 
a pair of forwardly projecting arms 122 and 124 respectively. Main section 
116 also includes stud 126 threaded therein to be receivable in slot 106 
to guide block 114 in reciprocating motion within housing 98. The limits 
of the reciprocating motion of block 114 are established by the length and 
position of slot 106. 
As mentioned previously plates 120 carry a pair of arms each projecting 
forwardly therefrom. Arms 122 extend from the upper plate 120 while arms 
124 extend from the lower plate 120. As seen in FIG. 4, the plates 120 are 
essentially identical but they are of opposite hand in position, that is, 
arm 122a is similar to arm 124b and arm 122b is similar to arm 124a. There 
is a gap 128 between the left and right arms, that gap being greater than 
the diameter of bushings 104. FIG. 4 illustrates as well that each of the 
arms 122a and 124b carries a cylindrical stud 130 which projects inwardly 
towards the arm directly opposite while the arm 122b carries a cylindrical 
stud 132 which projects outwardly therefrom, stud 132 being positioned for 
reception in slot 108 of top plate 100. 
Sandwiched between the upper arms 122 and the lower arms 124 are three 
circular plates 134, 136 and 138 (FIGS. 3a and 3b). Plates 134 and 138 are 
similar and are shown in plan view in FIG. 3c while plate 136 is shown in 
plan in FIG. 3d. Plates 134, 138 have a central opening 140, a radially 
directed slot 142 sized to receive a stud 130 and a projecting cylindrical 
housing 144 extending from one planar surface adjacent the periphery. 
Housing 144 has a cylindrical bore 146 communicating therefrom through the 
plate body, the bore 146 receiving a plug 148 slidable therein. The plug 
is biased outwardly of the housing 144 by a compression spring 150. The 
outer end of each plug carries a male ratchet tooth 152, generally 
triangular in profile. 
Plate 136, shown in FIGS. 3a, 3b and 3d is slightly smaller in diameter 
than plates 134, 138 and has a central boss 154 projecting outwardly from 
each surface (FIGS. 3a and 3b). The diameter of each boss is such as to be 
receivable in bore 140 in each of the plates 134, 138 to act as a bushing 
therefor. In addition there is a bore 156 extending through the bosses 154 
and plate 136 so as to receive shaft 90. The upper and lower surfaces of 
plate 134 each carries a pair of diametrically opposed female ratchet 
teeth 158, each tooth including a generally vertical section 160 and a 
sloping section 162. As can be seen in FIG. 3d the upper and lower teeth 
are circumferentially offset from each other but they are all oriented so 
as to impart uniform rotation to plate 136, counterclockwise as in FIG. 
3d. Shaft 90 can be keyed to plate 136 so as to rotate therewith by 
utilizing set screws receivable in threaded radial holes 164. 
Reverting to FIGS. 1 and 2 it is seen that drive assembly 96 is connected 
to a bearing block 166 which is adapted for vertical reciprocating 
movement on a pair of vertically oriented guide rods 168 held between 
frame members 16 and 18. A vertically oriented drive cylinder 170 is 
positioned between frame member 18 and bearing block 166 to impart the 
vertical reciprocating movement to the bearing block 166 and the drive 
assembly 96. Another cylinder 172 is affixed to one edge of bearing block 
166, the cylinder having a stop face 174 at its free end adapted to engage 
the side surface of a case 48. 
Finally an L-shaped framework 176 is affixed to frame members 22 and 30 so 
as to be supported above inlet conveyor 44. Framework 176 carries a 
cylinder 178 which is connected via a clevis to a rod 180 which in turn 
can pivot on pin 182 between generally vertical and generally horizontal 
attitudes. 
The operation of the present invention will now be described with reference 
to the simplified schematic of FIG. 5 and the structural details of FIGS. 
1 to 6. It is assumed that divider assembly 96 is in a lowered position 
(cylinder 170 retracted) in a case 48 with the divider vanes located as 
shown in FIGS. 1 and 2, defining four compartments 184. It is seen from 
FIG. 2 that the compartments 184 are elongated with the major axis of each 
being perpendicular to that of the adjacent compartment. It is also 
assumed that there is an empty case positioned between push arms 68a and 
68b. 
Control of the sequence of operations is provided by a timing wheel 186 
(FIG. 6) mounted for rotation in a yoke 188 (FIG. 5). Timing wheel 186 has 
a plurality of apertures arranged at various locations concentric to the 
rotational axis, namely outer apertures 190 (two in number), adjacent 
apertures 192 (four in number), inner apertures 194 (two in number), and 
innermost segmental apertures 198 (two in number). The angular separation 
between apertures 190, 192, 194 is 45.degree.. Rotation of timing wheel 
186 is provided by a spring return cylinder 198 operating through a 
ratchet mechanism (not shown) so that rotation of the timing wheel is 
unidirectional. 
Referring now to FIG. 5 pressurized air is provided via the conduit 
labelled "AIR IN", that air being directed to yoke 188 via four vertically 
aligned branch lines W, X, Y, Z, to pilot valves 200, 202, 204 and to 
mechanical valves B, C, D, E, F, G and H. 
With the divider assembly positioned as mentioned above, a full bale is 
directed along conveyor 74 until it enters diverter 78 and actuates 
mechanical switch 82 ("A" in FIG. 5). "A" is a 4-way spring operated valve 
and it normally is open to ensure that diverter cylinder 80 is retracted. 
Actuation of valve A pressurizes cylinder 80 to move the diverter from a 
position overlying conveyor 74 laterally (to the right as in FIG. 2) to a 
position overlying the adjacent compartment 184 in case 48. The bale drops 
into the compartment releasing switch A and causing the retraction of 
cylinder 80. During the retraction of cylinder 80 a cam mounted on the rod 
thereof activates mechanical switch B which in turn pressurizes cylinder 
198 to rotate timing wheel 186 through 45.degree.. This rotation brings an 
aperture 192 into alignment with branch line Y providing a pneumatic 
connection with pilot valve 206 which permits drive cylinder 110 to 
extend. Extension of drive cylinder 110 causes stud 130 on arm 122a and 
stud 130 on arm 124b to engage via slots 142 in their respective plates 
134 and 138 causing plate 134 to rotate counterclockwise and plate 138 to 
rotate clockwise (as in FIG. 3). Rotation of plate 134 brings the male 
ratchet tooth 152 extending therefrom into registry with one of the female 
ratchet teeth 158 on the upper surface of plate 136 causing 
counterclockwise rotation thereof. The male ratchet tooth 152 on plate 138 
is driven back into its bore 146 as it rides across the lower surface of 
plate 136. At the full extension of cylinder 110 the lower ratchet teeth 
will engage and the divider assembly, via shaft 90 and hub 88 will have 
rotated through 90.degree., causing rotation of case 48 also through 
90.degree. to thereby bring an empty compartment 184 adjacent diverter 78. 
During extension of cylinder 110, a mechanical switch K is actuated to 
cause operation of cylinder 172, the stop face of which engages the side 
of case 48 to aid in the rotation thereof. Switch K remains actuated only 
during a portion of the extension of cylinder 110 and hence when the case 
has reached its desired orientation switch K is deactivated and cylinder 
172 returns to its retracted position under the influence of an internal 
spring. 
The second bale, entering diverter 78 sets the above steps in motion again 
with the exception that rotation of the divider assembly and the case is 
achieved by retraction of cylinder 110 with plate 136 and shaft 90 being 
driven by engagement of the lower ratchet teeth 152, 158. Thus plate 138 
rotates counterclockwise and plate 134 rotates clockwise, with the upper 
male tooth 152 riding over the upper surface of plate 134 to eventually 
engage in the diametrically opposed female tooth 158. Control for this 
portion of the operation is achieved since the next aperture 190 has come 
into registry with branch line Z causing operation of pilot valve 208, 
pilot valve 206 being inoperative. 
The third bale repeats the operation initiated by the first bale, as the 
next aperture 192 is brought into registry with branch line Y and cylinder 
110 again retracts to rotate the divider assembly through 90.degree., 
bringing the last compartment 184 adjacent diverter 78. 
During the foregoing steps, segmental aperture 196 has been in registry 
with branch line W and hence cylinder 50 has been in an extended position, 
controlled by pilot valve 204. 
When the fourth bale has entered its compartment, aperture 194 is brought 
into registry with branch line X and pilot valve 202 is actuated to 
pressurize cylinder 170, extending the cylinder and raising the divider 
assembly 84 so that divider vanes 92 leave the full case. 
Since there are empty cases waiting in line mechanical switch G will have 
been depressed by a waiting empty case so as to retract cylinder 178 
causing stop rod 180 to enter the case approaching push bar 68a and 
prevent its inadvertent entry into the ready area between bars 68a and 68b 
inasmuch as inlet conveyor 44 is always operating. There will, of course 
be a case in the ready area between arms 68a and 68b, arm 68b being 
normally down due to retraction of the cylinders 66b. This is controlled 
by mechanical switch E which is actuated when cylinder 50 is in its 
extended position. Thus, when the divider assembly has lifted out of the 
full case, cylinder 50 is still extended, push bar 68b is down and there 
is a case between bars 68a and 68b. This latter case will depress switch H 
which, if pilot valve 210 is operated will cause cylinder 66a to retract 
and lower push bar 68a behind that case. 
When lift cylinder 170 has reached full extension it will operate switch C 
which causes cylinder 50 to retract and pilot valve 210 to permit the 
lowering of arm 68a. Arm 68b is already lowered (via switch E) and hence 
arm 68b will engage the full case as arm 68a engages the next empty case, 
both cases progressing in the same direction so that the full case is fed 
to the output conveyor 46 and the empty case is brought into the operating 
position below divider assembly 84. When cylinder 50 is fully retracted 
switch F is activated to cause divider 86 to lower into the empty case and 
cylinders 66a, 66b to extend, bringing arms 68a, 68b to a vertical 
orientation so that they can bypass the empty case and the next case to 
enter into the ready position between arms 68a, 68b. Retraction of 
cylinder 170 activates switch D to cause extension of cylinder 50 to its 
ready position. When switch E is again struck it will cause the lowering 
of arm 68b and the raising of arm 180 so that the next empty case can 
enter the ready area. The case following that case engages switch G to 
bring the stop arm 180 again to its lowered position. 
It should also be pointed out that switch D is a 4-way switch and that when 
cylinder 170 is extended it operates pilot valve 200 to disable switch A 
so that no bales will be inadvertently deposited in the mechanism during 
the case-changing sequence. 
The result of the above operation is shown in FIG. 7 with there being four 
bales 212 of packaged milk in a case 48, the bales being symmetrically 
positioned for ease of handling. 
A second embodiment is illustrated in plan view in FIG. 8 wherein it is 
seen that a second inlet conveyor 74a is located so that its diverter 78a 
will deposit a bale in a compartment 184 diametrically opposed to the 
compartment filled by diverter 78. Thus two compartments can be filled 
simultaneously and it is only necessary to rotate the divider and case 
through 90.degree. before the case is filled as opposed to 270.degree. of 
rotation when only a single diverter is used. This embodiment would 
require a new timing wheel 186 but such would be easy to devise. 
It is evident from the above that variations in the basic invention are 
possible and may occur to someone skilled in the art. For example the 
pneumatic circuitry could be simplified by replacing the timing wheel with 
a camming mechanism. This would reduce the complexity of the circuit and 
would also result in perhaps a more positive operation by avoiding the 
possibility of misalignment between the conduits W, X, Y, Z, and the 
appropriate aperture in the timing wheel 186. Accordingly the scope of 
protection to be afforded the present invention should be determined only 
from the appended claims.