Direct transfer sorting system

Articles to be sorted are loaded into carriers which move along a predetermined path that has groups of receptacles under and adjacent to it. Each carrier has gates or doors which are normally "closed" to define a bottom that can hold an article within that carrier, but which can be "opened" to release that article for direct transfer into a selected one of the receptacles, all of which are positioned below the level of that carrier. The gates or doors of the carriers are arranged so they can selectively and directly transfer articles into the centermost of a group of transversely-positioned receptacles, into the receptacle that is disposed outwardly of that centermost receptacle, or into the receptacle that is disposed inwardly of that centermost receptacle. As a result, the direct transfer sorting system of the present invention obviates the bulky and expensive chutes and guides which have been required by prior sorting systems.

SUMMARY OF THE INVENTION 
Articles to be sorted are loaded into carriers which move along a 
predetermined path that has groups of receptacles below and adjacent to 
it. Each carrier has gates or doors which are normally "closed" to define 
a bottom that can hold an article within that carrier, but which can be 
"opened" to release that article for direct transfer into a selected one 
of the receptacles. The gates or doors of the carriers are arranged so 
they can selectively and directly transfer articles into the centermost of 
a group of transversely-positioned receptacles, into the receptacle that 
is disposed outwardly of that centermost receptacle, or into the 
receptacle that is disposed inwardly of that centermost receptacle. As a 
result, the direct transfer sorting system of the present invention 
obviates the bulky and expensive chutes and guides which have been 
required by prior sorting systems.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring to the drawing in detail, the numeral 20 generally denotes a 
direct transfer sorting system which embodies the principles and teachings 
of the present invention. That system has a number of uprights 22; and 
parts of those uprights are shown in FIG. 1. Those uprights are preferably 
secured to the floor of the space in which the system 20 is mounted; and 
they are arranged in spaced pairs. Beams 24 are secured to, and extend 
laterally outwardly beyond, the tops of the uprights 22 to support an 
elongated track 26. As shown particularly by FIG. 4, that track is a deep, 
horizontal, outwardly-facing channel; and, as shown by FIG. 1, that track 
has elongated straight sections at the sides and ends thereof which are 
connected by arcuate sections. As a result, the track 26 provides a deep, 
continuous, horizontal, outwardly-facing elongated recess. Where desired, 
access doors or open areas may be provided in the track 26 for insertion 
or removal of a sprocket chain 32 or for other work on the sorting system. 
Inverted U-shaped brackets 28 extend upwardly from the top of the track 
26, adjacent the ends of the beams 24 and also adjacent other portions of 
that track; and those brackets support a second track 30. As shown 
particularly by FIG. 4, that second track is a shallow, horizontal, 
inwardly-facing channel which confronts the deeper channel 26. As shown 
particularly by FIG. 1, the track 30 is longer than, but is parallel to, 
the track 26: and hence the two tracks provide continuous, confronting, 
parallel, trackways. 
The sprocket chain 32 is guided by a chainguide 33 at the inner face of the 
closed end of the track 26, as shown by FIG. 4. Connecting links 34 are 
secured to the chain 32; and these connecting links have threaded 
receptacles 39 in the free ends thereof. Those threaded receptacles 
receive the free ends of stub shafts 44 that are fixedly secured to the 
right hand sides of carriers 36 by shaft mountings 46, as shown by FIG. 4. 
Each carrier 36 can have two stub shafts 44 secured to it or can have one 
stub shaft 44, plus a stub shaft that does not engage a connecting link, 
secured to it. Rollers 50 are mounted on the stub shafts 44 by suitable 
anti-friction bearings 41; and those rollers are supported and confined by 
the track 26. Stub shafts 40 are secured to the opposite sides of the 
carriers 36 by shaft mountings 42; and rollers 48 are mounted on those 
stub shafts, by anti-friction bearings, to be supported and confined by 
the track 30, as shown by FIG. 4. As indicated by FIG. 3, each carrier has 
one or more rollers 48, and each carrier also has one or more rollers 50; 
but each carrier must have at least three rollers. 
Each carrier 36 has two broad planar sides and two narrow planar ends to 
make each of those carriers rectangular in plan view. Outwardly-directed 
upper portions 38 are provided for the walls and ends of each carrier to 
facilitate the introduction of articles into those carriers. If desired, 
the portions 38 could be deleted. 
The numeral 52 denotes a spring-equipped, piano-type hinge that has one 
plate thereof attached to the lower portion of the outer surface of the 
outer broad planar side of a carrier 36; and it has the other plate 
thereof attached to the upper portion of a gate or door 54. That gate has 
a number of elongated, spaced-apart fingers 58; and each of those fingers 
has an upwardly-projecting, elongated, stiffening rib 56 therein. A 
generally trapezoidal abutment 59, which is shown by dashed lines in FIGS. 
3 and 5, is provided at the lefthand end of the gate 54 adjacent the upper 
edge of that gate. That abutment extends outwardly beyond the lefthand end 
of the carrier 36 as that carrier is viewed in FIG. 3. 
The numeral 60 denotes a spring-equipped, piano-type hinge which has one 
plate thereof secured to the lower portion of the outer surface of the 
inner broad planar side of the carrier 36; and it has the other plate 
thereof secured to the upper portion of a gate or door 62. That gate has a 
number of elongated, spaced-apart fingers 66; and each of those fingers 
has an upwardly-projecting, elongated, stiffening rib 64 therein. A 
generally trapezoidal abutment 68, which is best shown in FIG. 3, is 
provided at the righthand end of the gate 62 adjacent the upper edge of 
that gate. That abutment extends outwardly beyond the righthand end of the 
carrier 36 as that carrier is viewed in FIG. 3. The hinges 52 and 60 mount 
the gates 54 and 62 so the fingers 58 fit between and extend beyond the 
fingers 66, and vice versa. In doing so, those fingers positively keep any 
article from being accidentally released from any carrier. 
The upper plates of the hinges 52 and 60 are secured to the exterior 
surfaces of the broad planar sides of the carrier 36, as shown by FIG. 4, 
so those plates will not interfere with the free downward movement of 
articles into and through that carrier. The lower plates of those hinges 
are secured to the inner faces of the gates 54 and 62, as shown by FIG. 4, 
so those gates will not interfere with free movement of articles onto and 
along the lengths of the inner faces of those gates. 
The normal position of the gate 54 is shown by solid lines in FIGS. 2 and 
4; and the normal position of the gate 62 is shown by solid lines in FIG. 
2. The springs of the hinge 52 bias the gate 54 for clockwise rotation in 
FIG. 4; and the springs of the hinge 60 bias the gate 62 for counter 
clockwise rotation in that view. The gate 54 can be permitted to rotate 
downwardly in the clockwise direction to a vertical position that is shown 
by dashed lines in FIGS. 2 and 4; or it can be permitted to rotate even 
further in that direction to a dashed-line position in FIG. 2 wherein it 
inclines downwardly from upper right to lower left. The gate 62 can be 
permitted to rotate downwardly in the counter clockwise direction to a 
vertical position that is shown by dashed lines in FIGS. 2 and 4; or it 
can be permitted to rotate even further in that direction to a solid-line 
position in FIG. 4 wherein it inclines downwardly from upper left to lower 
right. Although the springs of the hinges 52 and 60 bias the gates 54 and 
62 for prompt movement into the dashed-line, inclined positions shown in 
FIG. 2--wherein those gates incline downwardly and away from the carrier 
36--those gates are normally held in the solid-line positions of FIG. 2 by 
the engagement between abutment 59 and a latch block 6 and by the 
engagement between abutment 68 and a latch block 72. 
The latch block 72 is rotatably secured to the righthand end of the carrier 
36, as that carrier is viewed in FIG. 3, by a spring-equipped, piano-type 
hinge 70. One plate of that hinge is secured to the righthand end of the 
carrier 36, and the other plate is secured to the top of the latch block 
72; and the spring of that hinge urges that latch block to rotate in the 
clockwise direction into a position which is parallel to that righthand 
end. The latch block 72 has a stop 74 thereon which will receive the 
abutment 68 and thereby hold the gate 62 in the solid-line position of 
FIG. 2, whenever that latch block occupies a position which is comparable 
to the position shown for the latch block 86 in FIG. 3. The latch block 72 
has a second stop 76 which will permit the springs of the hinge 60 to 
rotate the gate 62 to the dashed-line vertical position shown by FIGS. 2 
and 4 until the abutment 68 engages and is held by that stop. That latch 
block has a third stop 78 which will enable the springs of the hinge 60 to 
rotate the gate 62 to the dashed-line inclined position which extends from 
upper left to lower right in FIG. 2 until the abutment 68 engages, and is 
held by that stop. The numeral 80 denotes an elongated rod which has one 
end thereof threaded and seated within a threaded hole 85 adjacent one end 
of the latch block 72, as shown particularly by FIG. 7. A further threaded 
hole 83 is provided adjacent the other end of that latch block. Only one 
of the threaded holes 83 and 85 will be used to receive an elongated rod. 
The latch block 86 is identical to the latch block 72; but it has the 
threaded end of an elongated rod 88 seated in the opening 83 thereof; 
whereas the latch block 72 has the threaded end of the elongated rod 80 
seated in the opening 85 thereof. The latch block 86 is rotatably secured 
to the lefthand end of the carrier 36, as that carrier is viewed in FIG. 
3, by a spring-equipped, piano-type hinge 84. One plate of that hinge is 
secured to the lefthand end of the carrier 36, and the other plate is 
secured to the top of the latch block 86; and the spring of that hinge 
urges that latch block to rotate in the counter clockwise direction into 
the position shown by FIG. 3. Making the latch blocks 72 and 86 identical 
reduces the cost of making those latch blocks. It is only necessary for an 
assembler to insert the threaded ends of the elongated rods 80 into the 
threaded holes 85 of the latch blocks 72, and to insert the threaded ends 
of the elongate rods 88 into the threaded holes 83 of the latch blocks 86. 
The stops 74, 76 and 78 on the latch block 86 will coact with the abutment 
59 on the gate 54 to establish a normal, solid-line position for that gate 
in FIGS. 2 and 4, and an inclined solid-line position for that gate in 
FIG. 4. When the latch block 86 is held in the position shown by FIG. 3, 
by the springs of hinge 84, the stop 74 thereon will hold the gate 62 in 
the solid-line position of FIG. 2. When that latch block is in a position 
comparable to that of the latch block 72 in FIG. 3, the stop 78 and the 
springs of hinge 60 will hold the gate 62 in the inclined solid-line 
position of FIG. 4; and, when the latch block 86 is in a position 
intermediate those of that latch block and of the latch block 72 in FIG. 
3, the stop 76 and the springs of hinge 60 will hold the gate 62 in the 
dashed-line vertical position of FIGS. 2 and 4. 
The elongated rod 80 has a thin, generally-triangular cam 82 formed 
integrally with, and extending upwardly from, the free end thereof; and 
the elongated rod 88 has an identical cam 92 formed integrally with, and 
extending upwardly from, the free end thereof. The fact that the cams 82 
and 92 are thin enables them to be disposed immediately adjacent each 
other, as shown in FIG. 5. The springs of the piano-type hinges 70 and 84 
normally hold the cams 82 and 92 in the upper position shown by solid 
lines for the cam 92 in FIGS. 3 and 4. However, those springs can yield to 
permit those cams to be moved downwardly to intermediate positions 
indicated by dashed-lines for the cam 92 in FIG. 3. In fact, those springs 
can yield to permit those cams to be moved downwardly to fully-moved 
positions indicated by the position of cam 82 in FIGS. 3 and 4. The cam 82 
will be in its normal position whenever the cam 92 is in its fully-moved 
position, and vice versa. However, when either of the cams 82 and 92 is in 
its intermediate position, the other cam also will be in its intermediate 
position. 
The numeral 94 denotes a rotary solenoid which is secured to a bracket 93 
which, in turn, is secured to the outer track 30, as indicated 
particularly by FIG. 4. The shaft 96 of that solenoid supports the hub of 
a cam 98 which has an inverted L-shaped arm 100, an abutment 102 which 
extends downwardly to the level of the lower end of the arm 100, and an 
abutment 104 that is displaced above the lower ends of arm 100 and of 
abutment 102 As shown particularly by FIG. 5, the abutments 102 and 104 
lie in the same plane, and the L-shaped arm 100 is displaced ninety 
degrees from that plane. The normal position for the cam 98 is one hundred 
and eighty degrees from the position shown in FIG. 5; namely, a position 
wherein the arm 100 extends away from, rather than toward, the paths of 
travel of the cams 82 and 92, wherein the abutment 104 occupies the 
position occupied by the abutment 102 in FIG. 5, and wherein the abutment 
102 occupies the position occupied by the abutment 104 in FIG. 5. 
Different rotary solenoids could be used; but a Ledex 12-position rotary 
solenoid stepping switch, part number 250-404-244, could be used by 
substituting the cam 98 for the "circuit decks" of that switch. 
A four-position, programmable, reciprocating solenoid is preferred over a 
rotary solenoid; because the plunger of a reciprocating solenoid can apply 
stronger forces to cams 82 and 92 than can a rotary solenoid. Such a 
solenoid is shown in FIGS. 16-19; and it is the preferred form of solenoid 
for the sorting system of the present invention. That solenoid includes a 
housing 210, a plunger 212, and an actuator 214. For clarity of showing, 
that actuator is shown in the positions it occupies when it is intended to 
actuate neither cam 82 nor cam 92 (FIG. 16), to actuate only cam 92 (FIG. 
17), to actuate only cam 82 (FIG. 18), or to actuate both of those cams 
(FIG. 19). The cams 82 and 92 are shown in their normal, upper positions; 
although one or both of them will have been moved downwardly by one or the 
other of the abutments 216 and 218 on actuator 214 as those cams moved 
forwardly past that actuator at right angles to the plane of the paper. 
Those cams will remain in their downward positions until the gates or 
doors that are associated with them are re-closed. 
The housing 210 has an internal spring which normally holds the plunger 212 
in the retracted position shown by FIG. 16; but that spring can yield to 
permit that plunger to move to any one of three extended positions that 
are shown by FIGS. 17-19. The housing 210 also has a tapped coil or a 
plurality of coils therein which can move the plunger 212 to, and hold it 
in, any one of those extended positions. The plunger 212 has an a circular 
cross section to keep it from rotating relative to the housing 210 as it 
reciprocates relative to that housing. A typical four position solenoid is 
marketed as an Airpax Linear Displacement Solenoid. 
The abutment 216 on actuator 214 will perform the functions of the abutment 
104 on the cam 98 in FIGS. 3 and 5. Specifically, the solenoid can be 
energized to cause the plunger 212 to dispose the abutment 216 in position 
to engage both of the cams 82 and 92, which are shown in their normal, 
upper positions by FIG. 19; and the resulting downward movements of those 
cams, to the dashed-line lower position for cam 92 in FIG. 3 as the 
carrier 36 moved forwardly past the housing 210, freed both gates 54 and 
62 for movement to the vertical positions shown by dashed lines in FIGS. 2 
and 4. As those gates were subsequently re-closed those cams returned to 
the normal, upper positions shown by FIG. 19. The abutment 218 on the 
actuator 214 will selectively perform the functions of both of the 
abutments 100 and 102 in FIGS. 3-5. Specifically, the solenoid can be 
energized to dispose the abutment 218 in position to engage the cam 82, 
which is shown in its normal, upper position by FIG. 18; and the resulting 
downward movement of that cam, to the lower position shown by FIG. 3 as 
the carrier 36 moved downwardly past the housing 210, freed the gate 62 
for movement to the inclined position shown by solid lines in FIG. 4. As 
that gate was subsequently re-closed, that cam returned to the normal 
upper position of FIG. 18. Alternatively, the solenoid can be energized to 
dispose the abutment 218 in position to engage the cam 92, which is shown 
in its normal, upper position by FIG. 17; and the resulting downward 
movement of that cam to a lower position corresponding to the position of 
cam 82 in FIG. 3 as the carrier 36 moved forwardly past the housing 210, 
freed the gate 54 for movement to the dashed-line, inclined position of 
FIGS. 2 and 4. As that gate was subsequently re-closed, that cam returned 
to the normal upper position of FIG. 17. 
The engagement between the acircular plunger 212 and the guide therefore in 
the housing 210 will be loose enough to permit ready reciprocation of that 
plunger relative to that housing, but will be close enough to enable that 
plunger and the actuator 214 to force the cams 82 and 92 to move 
downwardly to any of the positions indicated by FIG. 2. If very heavy 
objects were to be loaded into the carriers 36, with consequent very heavy 
frictional forces between the latch blocks 72 and 86 and the abutments 68 
and 59, a back-up plate could be mounted behind the upper portion of the 
actuator 214. Such a back-up plate would enable the actuator 214 to force 
the cams 82 and 92 to move downwardly in any of the positions indicated by 
FIG. 3 even when very heavy objects were loaded into the carriers 36. 
The direct transfer sorting system 20 will have a large number of carriers 
36; and it will have a large number of groups of transversely-arranged 
receptacles disposed below the level of those carriers. The numerals 112, 
114, 116, 118, 120, 122, 124, 126, 128 and 130 denote groups of three 
transversely-arranged receptacles which are arranged along the lengths of 
straight sections of the carrier-supporting tracks 26 and 30. The 
centermost receptacle of each group of three transversely-arranged 
receptacles should be mounted directly under the path of the carriers, 
another of those receptacles should be mounted inwardly of that path, and 
the third of those receptacles should be mounted outwardly of that path. 
If desired, groups of two transversely-arranged receptacles could be 
mounted adjacent three of the arcuate sections of the track 30 of the 
direct transfer sorting system 20. In such event, one of the two 
receptacles of each group of two transversely-arranged receptacles should 
be mounted directly under the path of the carriers, and the other of those 
receptacles should be mounted outwardly of that path. 
A rotary solenoid 94 and a cam 98 must be mounted a short distance in 
advance of the longitudinal center of each group of transversely-arranged 
receptacles. Such an arrangement will compensate for the trajectory in 
which an article will tend to follow as it is released from a carrier 36. 
Alternatively, a four-position, programmable, reciprocating solenoid with 
its three-abutment plunger could be mounted a short distance in advance of 
the longitudinal center of each group of transversely-arranged 
receptacles. 
The numeral 106 denotes a driving motor, which has a suitable 
speed-reducing gear train associated with it, and that motor and gear 
train will drive a sprocket which, in turn, will drive the chain 32. The 
motor 106 will be mounted on a support 108 adjacent one corner of the 
inner track 26. 
The numeral 110 generally denotes a loading mechanism which will direct 
articles into the various carriers 36 of the direct transfer sorting 
system 20, as those carriers are moved under that loading mechanism. The 
showing of the loading mechanism 110 is schematic in nature, and that 
mechanism is not shown in detail; because it is not, per se, a part of the 
present invention. That loading mechanism will preferably have transfer 
carriers that move above, and parallel to, the carriers 36 as the articles 
are transferred from those transfer carriers to the carriers 36. 
One group of three transversely-arranged receptacles is shown in FIG. 2; 
and the centermost receptacle 138 is located directly under the path of 
the carriers 36, the receptacle 140 is located well inwardly of that path, 
and the receptacle 136 is located well outwardly of that path. The 
structure and details of the receptacles are not critical; and hence the 
various receptacles are shown in the drawing as metal bins. However, the 
various receptacles can readily, and frequently will, be sacks that are 
held in position with the upper ends thereof open to receive articles 
released by the carriers 36. 
The numeral 144 generally denotes a gate-closing station wherein all of the 
gates 54 and 62, which are not in the normal, solid-line, "closed" 
positions of FIG. 2, will be automatically moved to those positions. As 
those gates are moved to their "closed" positions, the springs of the 
hinges 70 and 84 will dispose each of the latch blocks 72 and 86 in the 
closed-gate position shown for the latch block 86 in FIG. 3. That 
gate-closing station has brackets 146 and 152 which are secured to, and 
which depend downwardly from, a bracket 28 and a beam 24 adjacent arcuate 
portions of tracks 26 and 30 intermediate the group 130 of 
transversely-arranged receptacles and the loading mechanism 110. 
Horizontally-disposed plates 148 and 154 are secured to, and extend 
inwardly from, the lower ends of the brackets 146 and 152, respectively, 
and the inner edges of those plates confront each other. Those inner edges 
converge, as they are viewed from their front edges to their rear edges; 
and those inner edges are provided with noses 150 and 156 which are made 
from a tough, plastic material that has a low coefficient of friction. One 
such material is Teflon. 
The leading edges of the plates 148 and 154, and of the noses 150 and 156 
thereon, are spaced far enough apart to accommodate the upper portions of 
gates 54 and 62 which are in their "fully-moved" positions. The rear edges 
of the plates 148 and 154, and of the noses 150 and 156 thereon, are 
spaced close enough together to force the upper portions of any gates 54 
and 62, which are not in their "closed" positions as they are moved toward 
the gate-closing station 144, to move into such positions. 
The low coefficient of friction of the material of the noses 150 and 156, 
and the gradual closing action provided by those noses, will minimize any 
tendency of the gate-closing station to "wear" the leading edges of the 
upper portions of the gates 54 and 62. If any wear should be observed, 
U-shaped clips of wear-resisting material could be pressed onto, or 
otherwise secured to, those leading edges. 
The portions, of the bottom edges of the cams 82 and 92 which are remote 
from the hinges 70 and 84, respectively, are relieved. As a result, all 
portions of those bottom edges will be located above the levels of the 
upper faces of the plates 148 and 154 and of the gates 58 and 66--in all 
moved positions of those cams. Consequently, the cams 82 and 92 will not 
engage and be jammed against any parts of the sorting system. 
The motor 106 continuously drives the chain 32 in the same direction; and 
hence the carriers 36 continuously move in the same direction around the 
predetermined path that is defined by the tracks 26 and 30. Before each 
carrier reaches the loading mechanism 110, the noses 150 and 156 of the 
plates 148 and 154 of the gate-closing station 144 will force each gate of 
that carrier, which is not in its normal "closed" position, to move into 
that position. As the gates of the carriers are moved into their "closed" 
positions, the abutments 59 and 68 thereon will be moved into positions 
wherein they will be held by the stops 74 on the latch blocks 86 and 72 of 
the carriers. Those stops will keep those doors in their "closed" 
positions until such time as one or the other or both of the latch blocks 
72 and 86 are moved out of the normal positions indicated at the lefthand 
side of FIG. 3 for the latch block 86. 
The articles which are introduced into the carriers 36 will preferably be 
encoded with information which will cause the rotary solenoids 94, 
adjacent the various groups of transversely-arranged receptacles, to 
remain inactive until a carrier has moved an article close to a position 
where it should be released from that carrier. Immediately prior to the 
time a carrier moves an article into such a position, the direct transfer 
sorting system 20 will, in response to the previously-read encoded 
information on the article, cause the rotary solenoid 94 adjacent that 
position to become energized. If the article is to be directed into the 
central receptacle 138, the solenoid 94 will be actuated to cause the cam 
98 to dispose the abutment 104 in the paths of both of the cams 82 and 92. 
As the carrier then moves the inclined leading faces of those cams into 
engagement with that abutment, those cams will move downwardly to the 
intermediate position indicated by dashed lines for the cam 92 in FIG. 3; 
and, in those intermediate positions, the tops of the cams 82 and 92 will 
be at the level of the bottom edge of the abutment 104. As those cams are 
moved downwardly to those intermediate positions, the elongated rods 80 
and 88 will force the latch blocks 72 and 86 to rotate away from the 
normal positions thereof to positions intermediate the normal position 
indicated for the latch block 86 in FIG. 3 and the fully-moved position 
indicated for the latch block 72 in that view. As those latch blocks are 
moved to those intermediate positions, the stops 74 on those latch blocks 
will be moved out of register with the abutments 68 and 59. Thereupon, the 
springs of the hinge 52 will force the gate 54 to rotate in the clockwise 
direction from its normal, solid-line position to its dashed-line, 
vertical position in FIG. 2; and the springs of the hinge 60 will force 
the gate 62 to rotate in the counter clockwise direction from its normal, 
solid-line position to its dashed-line, vertical position in FIG. 2. The 
abutments 59 and 68 on the gates 54 and 62 will be intercepted and held by 
the stops 76 on the latch blocks 86 and 72; and, thereupon, the gates 54 
and 62 will guide the article as it is directly transferred from the 
carrier 36 into the receptacle 138. 
The tops of the receptacles 136, 13B and 140 must be below the levels of 
the arcuate paths that are followed by the lower ends of the fingers 58 
and 66 of the gates 54 and 62, as those gates move from their normal, 
solid-line "closed" positions to the dashed-line vertical positions, or to 
the dashed-line fully-moved positions of FIG. 2; because those gates tend 
to remain in any positions they assume as a result of the cam-induced 
rotation of the latch blocks 86 and 72. In fact, each gate 54 and 62 will 
remain in its assumed position until its carrier reaches the gate-closing 
station 144; which will then return all gates to the normal solid-line 
"closed" position of FIG. 2. 
If the article is to be transferred to the inner receptacle 140, rather 
than to the centermost receptacle 138, the rotary solenoid 94 will be 
actuated to rotate the cam 98 to the position shown by FIG. 5 wherein the 
bottom of the inverted L-shaped arm 100 will be in the path of the cam 82 
on the elongated rod 80 but will be out of the path of the cam 92 on the 
elongated rod 88. As a result, when the longitudinal midpoint of the 
carrier approaches the cam 98, the cam 92, the elongated rod 88 and the 
latch block 86 will be permitted to remain in the solid-line positions 
shown therefor by FIG. 3; but the cam 82 and the elongated rod 80 and the 
latch block 72 will be moved to the positions shown therefor by that view. 
Thereupon, the gate 62 will respond to the springs of the hinge 60 to 
rotate until the abutment 68 on that gate engages and is held by the stop 
78 on the latch block 72. As that abutment engages, and is held by, that 
stop, the gate 62 will be in the dashed-line inclined position which 
extends from upper left to lower right in FIG. 2; and hence that gate will 
be parallel to the gate 54 which is still in its normal, solid-line 
"closed" position. At this time, the article, which had been held within 
the carrier 36, will slide along the upper surfaces of the fingers 58 of 
the gate 54 and will be guided and confined by the gates 54 and 62 until 
it drops into the receptacle 140. Those gates will remain in those 
inclined positions until the carrier 36 again reaches the gate-closing 
station 144--at which time the gate 54 will be left in its "closed" 
position, but the gate 62 will be moved into its "closed" position At such 
time, the abutment 68 on that gate will move inwardly of the stop 74 on 
the latch block 72; and the springs of the hinge 70 will rotate that latch 
block to a position similar to that shown for the latch block 86 in FIG. 
3. 
If the article is to be transferred to the outermost receptacle 136, rather 
than to the centermost or inner receptacles 138 and 140, the rotary 
solenoid 94 adjacent the group of receptacles, which includes the 
receptacle 140, will be actuated to dispose the cam 98 in position to 
place the abutment 102 in the path of the cam 92. That abutment is so 
narrow that it will not extend into the path of the cam 82; and hence, as 
the carrier 36 moves the cam 92 into engagement with the abutment 102, the 
cam 82, the rod 80 and the latch block 72 will remain in their gate-closed 
positions and will permit the gate 62 to remain in the normal solid-line 
"closed" position of FIG. 2. However, the abutment 102 will cause the cam 
92 to move downwardly, and will thereby force the elongated rod 88 and the 
latch block 86 into positions which are comparable to those shown for the 
cam 82, the elongated rod 80 and the latch block 72 in FIG. 3. Thereupon, 
the gate 54 will respond to the springs within the hinge 52 to move to and 
through the dashed-line vertical position to the fully-moved inclined 
position in FIG. 2, wherein that gate inclines downwardly from upper right 
to lower left. At such time, the article which had been held by the 
carrier 36 will slide along the upper surface of the gate 62; and it will 
be guided and confined by that gate and the gate 54 until it drops into 
the receptacle 136. Those gates will remain in those inclined positions 
until the carrier 36 again moves into the gate-closing station 144. 
As shown particularly by FIG. 2, the gate 54 completely blocks access to 
the centermost receptacle 138 and to the outer receptacle 136, whenever 
that gate is in its normal, solid-line "closed" position. Similarly, the 
gate 62 completely blocks access to the receptacle 138 and to the inner 
receptacle 140, whenever it is in its normal solid-line "closed" position. 
This is important; because it means that even when the gate 62 is moved by 
the springs of the hinge 60 to the dashed-line, fully-moved, inclined 
position in FIG. 2, the gate 54 will positively keep any article within 
the carrier 36 from getting into either of the receptacles 136 and 138. 
Conversely, it means that when the gate 54 responds to the springs of the 
hinge 52 to move to the dashed-line, fully-moved inclined position of FIG. 
2, the gate 62 will positively keep any article within the carrier 36 from 
getting into either of the receptacles 138 and 140. Further, when the 
gates 54 and 62 are in their dashed-line vertical positions, they will 
keep articles within the carrier from getting into either of the 
receptacles 136 and 140. As a result, the gates 54 and 62 will coact to 
make certain that each article is directed to just one receptacle, and is 
guided all the way into that receptacle. 
The carriers 36 are mounted so each of them has a long axis in plan view 
which moves parallel to the path of movement of the chain 32; and such an 
arrangement is desirable, because it enables a group of receptacles to 
have the same length, along that path, which any one of those receptacles 
has along that path. However, if desired, the carriers could be mounted so 
each of them had a long axis in plan view which was transverse of the path 
of movement of the chain 32. In such event, the receptacles of each group 
of receptacles, would be arranged along, rather than transversely of, that 
path of movement. 
The latch blocks 72 and 86 and the gates 62 and 54 coact to hold an article 
until the carrier 36 reaches a predetermined group of receptacles; and 
then they coact to direct that article into a centermost, an inner, or an 
outer receptacle. If desired, the latch blocks 72 and 86 and the gates 62 
and 54 could be arranged to hold an article until the carrier 36 reached a 
predetermined group of just two receptacles; and then they could coact to 
direct that article into a receptacle directly below that carrier or into 
a laterally-spaced receptacle of such a group or, alternatively, into an 
inner or an outer receptacle of such a group. 
The use of spring-equipped hinges to bias the gates 54 and 62 for rotation, 
and the use of the latch blocks 86 and 72 to hold those gates in 
predetermined positions, are very useful where relatively-heavy articles 
are transported by the carriers 36. Also, it is useful where it is desired 
to free the carriers 36 from all electrical and electronic components. 
However, where light-weight articles are to be transported by the carriers 
36, rotary solenoids or other rotary actuators could replace the springs 
in hinges 52 and 60 and also could replace the latch blocks 72 and 86. 
The use of spring-equipped hinges to bias the gates 54 and 62 for rotation, 
and the use of the latch blocks 86 and 72 to hold those gates in 
predetermined positions, make the direct transfer sorting system 20 
extremely reliable and predictable; because each carrier has just eight 
moving parts: the two rollers 48, the two rollers 50, the two gates 54 and 
62, and the two latch blocks 86 and 72. The resulting reliability and 
predictability, plus the absence of any need for chutes or guides, make 
the direct transfer sorting system 20 very useful and desirable. 
If desired, the bottom of one or more of the carriers 36 could be 
constituted by a single gate or door instead of the two gates 54 and 62; 
and such an arrangement is shown by FIGS. 14 and 15. The numeral 160 
denotes a carrier which will preferably be very similar to the carrier 
36--having a hinge 168 like the hinge 52, a gate 164 like the gate 54, a 
latch block 172 similar to the latch block 86, a rod 182 like the rod 88, 
a cam 184 like the cam 92, a hinge 173 like the hinge 84, and rollers like 
the rollers 48 and 50. However, instead of having a hinge 60 and a gate 
62, the carrier 160 has downwardly-extending fingers 170 at the lower edge 
of one planar side thereof; and those fingers are spaced apart to 
accommodate the fingers 166 of the gate 164. The latch block has stops 
174, 176, 178 and 180 which can selectively engage one side of the gate 
164 and thereby selectively hold that gate in a fully-closed, horizontal 
position as shown by FIGS. 14 and 15, a first moved position wherein it is 
forty degrees below the horizontal, a second moved position wherein it is 
sixty-seven and one half degrees below the horizontal, and a third moved 
position wherein it is vertical. A receptacle 186, with a removable, 
sack-like bottom 200, has all portions of the top thereof positioned 
directly under the path of the carrier 160. A second receptacle 188, with 
a removable, sack-like bottom 202, has one side thereof in common with 
that side of receptacle 186 which is remote from the hinge 173 for the 
gate 164; and a third receptacle 190, with a removable, sack-like bottom 
204, has one side thereof in common with the other side of receptacle 188. 
The top of the receptacle 188 is set at a level above the top of the 
receptacle 186, the top of the receptacle 190 is set at a level above the 
top of the receptacle 188, and the tops of the three receptacles 186, 188 
and 190 are set as close as possible to the arc defined by the free edge 
of gate 164 The stiffening ribs of the fingers 166 in FIG. 15 are not 
shown in FIG. I4. 
As long as that gate is held in its fully-closed, horizontal position by 
the stop 174, the carrier 160 will hold any article deposited therein. 
When that gate is freed from the stop 174 and is then held by the stop 176 
in its first moved position, wherein its free edge is adjacent the common 
wall of receptacles 188 and 190, it will direct an article into the 
receptacle 190. When the gate 164 is freed from the stop 174 and is then 
held by the stop 178 in its second moved position, wherein its free edge 
is adjacent the common wall of receptacles 86 and 188, it will direct an 
article into the receptacle 188--either directly or by a rebound from that 
portion, of the common wall between receptacles 188 and 190, which 
projects above the top of the other wall of receptacle 188. When the gate 
164 is freed from the stop 174 and is then held by the stop 180 in its 
vertical position, wherein its free edge is adjacent the left-hand wall of 
receptacle 186, it will direct an article into that receptacle--either 
directly or by a rebound from that portion, of the common wall between 
receptacles 186 and 188, which projects above the top of the left-hand 
wall of receptacle 186. The downward rotation of the gate 164 will draw 
air downwardly through the carrier 160; and that air will help the article 
within that carrier move downwardly with that gate. In the event any 
light-weight articles tended to drift toward the receptacle 188 instead of 
falling into the receptacle 186 when the gate 164 is in its vertical 
position, the top of the receptacle 186 could be widened to extend beyond 
the side of the carrier path, and thereby displace the receptacle 188 even 
further laterally from the hinge 173 for the gate 164. The use of two 
gates per carrier is preferred over the use of one gate per carrier; 
because it permits wider-top receptacles to be used, and because the two 
gates provide closer and more positive guiding of articles into the 
receptacles. 
If desired, the gate-closing station 144 could be made to provide dynamic, 
rather than static, closing of the gates 54 and 62. For example, a pair of 
solenoids could be set at opposite sides of the path followed by the 
carriers; and pressure bars on the ends of the plungers thereof could move 
far enough toward each other to push the gates 54 and 62 into fully-closed 
position. 
A reader and a computer, of the type customarily used in sorting systems, 
will "read" the code on the articles to be sorted by the direct transfer 
sorting system 20; and it will provide the required actuations of the 
rotary solenoids 94 Such a reader and computer are not shown because they 
are not, per se, a part of the present invention. That computer will 
preferably determine which rotary solenoid 94 is to be actuated by 
counting the carriers as they move past a photoelectric or other 
commercially-available counter. 
The latch blocks 72 and 86 are useful and desirable; because each of them 
provides a holding function plus two positioning functions. However, if 
desired, the holding functions of the latch blocks could be performed by 
releasable stops, and the positioning functions of those latch blocks 
could be performed by pre-settable stops. The releasable stops would be 
mounted on the carrier 36 and could be selectively actuated by tripping 
mechanisms that were mounted on that carrier or that were mounted adjacent 
the path of that carrier; and the pre-settable stops would be mounted on 
the carrier 36 and could be pre-set at the time the code on the article 
was read, or could be pre-set as the carrier was moving from the loading 
location to an unloading location. 
The present invention provides direct and immediate transfer of an article 
from a carrier into one of a plurality of closely-adjacent receptacles, 
while eliminating all need of the chutes, guides and sub-conveyors that 
have been used in prior sorting systems. As a result, the present 
invention provides a relatively-inexpensive sorting system which provides 
reliable and quick transfer of articles from carrier to receptacle. 
Whereas the drawing and accompanying description have shown and described a 
preferred embodiment of the present invention it should be apparent to 
those skilled in the art that various changes may be made in the form of 
the invention without affecting the scope thereof.