Sleeving system

Abstract: An automatic slide sleeving system in which a sleeve (12) containing a plurality of pockets is moved past a rotatable member (40) to which a vacuum is applied thereby drawing the sleeve (12) along with the rotatable member (40) to a position under a movable head (44) where a second vacuum is applied pulling the pocket into an open condition and thereafter through an actuator mechanism (25), the slides which have been previously moved into position from a slide hopper (30) by a shuttle (48) are moved in to the open pockets by a tongue pusher (22-24) after which the vacuums are removed and the rotatable member (40) rotated thereby enabling the filled pockets on the sleeve (12) to be collected.

Description: 1. Field of the Invention. The present invention relates to an apparatus and method for inserting a product such as photographic slides into pockets of a sleeve member automatically in a continuous fashion. 2. Description of the Prior Art. In the film processing industry after slides have been mounted in cardboard or plastic frames, they are normally packaged into small boxes for shipping and handling. Usually this packing is accomplished by hand and such boxing techniques are not only costly but the box is rather heavy for mailing and the film cannot be viewed without removing the slides from the box which often results in fingerprint smudges. US-E-28,350 relates to methods and apparatus for advancing and loading a chain of bags, but does not relate to photographic slides. DE-A-3030545 discloses an apparatus for packaging photographic slides into envelopes. US-A-4055933 discloses a flexible transparent envelope for packaging photographic slides, and a method and apparatus for packaging the slides in the envelopes. SUMMARY OF THE INVENTION The present invention operates automatically to insert mounted slides into plastic sleeves so as to reduce the handling costs and to provide an attractive as well as light package for shipping or mailing. The plastic sleeves also protect the slide from damage due to fingerprints and other contamination and allow the slides to be visually scanned while in their packages. By arranging the pockets in rows, the sizing of the pockets can be made so that the sheets of slides can be fit into standard size envelopes currently used for mail order and over-the-counter sales. Furthermore, identification of slides for reorders of prints or extra slides may be accomplished by using write on areas of the sleeve or automatic retrieval of slides can be obtained with machinery that reads characters applied onto the sleeving pockets. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of a preferred embodiment of the present invention; Figure 2 is a top view of a portion of Figure 1; Figure 3 is a side view of Figure 1; Figure 4 is a cut away side view of Figure 2 taken along the section 4-4; Figure 5 is a cut away side view of Figure 2 taken along section 5-5; Figure 6 and 6A are a cut away top view of Figure 3 taken along section 6-6; Figure 7 is a cut away front view of Figure 2 taken along section 7-7; Figure 8 is a cut away front view of Figure 3 taken along section 8-8; Figure 9 is a perspective view of the sleeve material and pockets therein; Figure 10 is a side view of Figure 1 showing a mounter and an alternate form of hopper useful to combine the present invention automatically with the output of the mounter; and Figure 11 is an exploded view of rotating drum and vacuum manifold therefore. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to Fig. 1, a perspective view of the apparatus of the present invention is shown, mounted on a base member 10 and comprising the following major elements: (1) a roll 12 of sleeve material to be described in connection with Figure 9, mounted for free rotation on a pair of upright members 14 and 15 extending upwards from the base 10; (2) a tongue member 20 comprising three pusher tongues 22, 23 and 24 extending towards the left and an actuator member 25 extending toward the right. The tongue member 20 will be better described in connection with Figures 2, 3 and 8; (3) a vertical hopper 30 adapted to contain a pile of mounted photographic slides 32 or other similar products which are to be inserted into the pockets on the sleeve material 12; (4) a multi-sided rotatable member or drum 40 which will be better described in connection with Figures 2 and 4, for pulling and positioning the sleeve material from roll 12 through the apparatus while the slides are being inserted; (5) a lifter head 44 operated by actuating mechanism 46 to open the pockets in the sleeve material 12 while such sleeve material is being held by the rotatable member 40 so that slides may be inserted. The lifter head 44 will be better described in connection with Figures 2, 3, 4 and 5; (6) a shuttle member 48 to be better described in connection with Figures 6, 6a and 7 operable to move slides from the hopper 30 into a position where the pusher members 22, 23 and 24 can move the slides into the pockets open between rotatable member 40 and lifter head 44; (7) a pneumatic actuator assembly 52 operable to control the actuation of the vacuums and various actuators causing motion of the elements of the present invention; and (8) a control assembly 55 which may include a computer and timer for determining the proper actuating times and positions for the elements of the present invention. The sleeve material 12 may be of the type manufactured and sold by the Unicolor Division of Protosystems Inc. and identified as slide album pages. The vacuum sources and the pneumatic actuator in the assembly 52 may be any standard vacuum and air compressor. The controller 55 may be a programmable logic controller such as that manufactured and sold by Crouzet Inc. as Model Number CMP 31. In operation the rotatable drum 40 is connected to the assembly 52 in such a way that a vacuum is applied to two surfaces of the several-faced drum, and more particularly, to that surface which first receives the sleeve material 12 and that surface which lies adjacent the lifter head 44. As the sleeve material from roll 12 passes over to the drum 40, a vacuum applied to the interior of the drum acting through a plurality of holes in the surface operates to hold the sleeve material onto that surface of the drum. As the drum 40 rotates, the sleeve material is carried along and is brought up to a position just underneath the lifter head 44. A second vacuum is applied from assembly 52 to the lifter head 44 so as to pull the upper surface of the sleeve material thereagainst. The actuator 46 thereafter lifts slightly thus opening the pocket in the sleeve material for insertion of the slides. During this time, the shuttle 48 moves under the hopper 30 to receive one or more slides at spaced positions along the shuttle 48. Thereafter, the shuttle 48 is moved back to the position shown, and the three slides are lying in a position adjacent the openings of the pockets in the sleeve material between drum 40 and lifting head 44. At this time, actuator 25 is actuated moving the pusher tongues 22, 23 and 24 against the slides and pushing them into the open pockets on the sleeve material. The controller 55 then causes the actuator 46 to move the lifter 44 away from the sleeve material. The drum 40 then rotates to another position where the next row of pockets is now inserted between the drum 40 and the lifter head 44 while the filled row is released by cessation of the vacuum so that the sleeve is removable from the drum 40 for storage packing or mailing. Referring now to Figure 2 wherein elements that are shown in Figure 1 have the same reference numerals, a top view of Figure 1 is seen with the roll 12 of sleeve material shown supported by the upright members 14 and 15. The tongue member 20 and the three pusher tongues 22, 23 and 24 are shown connected to the actuator 25 by an actuator piston 60. Three slides are shown in the shuttle 48 identified by reference numerals 70, 71 and 72 and they are seen to be located in the paths of the pusher tongues 22, 23 and 24, respectively. It will be understood that when the actuator member 25 is energized from the pneumatic actuator assembly 52 the piston 60 will cause the tongue pushers 22, 23 and 24 to move to the right thereby pushing the slides 70, 71 and 72 to the right to a position under the lifter head 44 and into the open pockets on the sleeve material coming from roll 12. Slides 70, 71 and 72 are shown contained in the shuttle 48 in three receiving areas, better shown in Figure 7 as receiving areas 75, 76 and 77, respectively. Shuttle member 48 is actuated by a pneumatic actuator 80 having a pneumatic connection 82 which is connected to the pneumatic actuator assembly 52. After the slides 70, 71 and 72 are pushed to the right and into pockets on the sleeve material 12, actuator 25 operating through piston 60 withdraws the pusher tongues 22, 23 and 24 to the left, as shown in Figure 2, at which time the empty shuttle 48 will be actuated by pneumatic actuator 80 to move upwardly in Figure 2 underneath the hopper 30 for receipt of further slides. More particularly in Figure 7, a sensor 78 in hopper 30 senses a slide at the bottom position and notifies the control assembly which then actuates the shuttle 48 and moves it to where the slide at the bottom of the pile at hopper 30 will move into the receiving area 77 occupied by slide 72 in Figure 2. The sensor 78 in hopper 30 then senses another slide positioned at the bottom and notifies the control assembly 55. Further motion of shuttle 48 results causing the next slide in the pile to fall into the receiving area 76 occupied by slide 71 in Figure 2. The sensor 78 in hopper 30 again senses a slide positioned at the bottom and again notifies the control assembly 55. Thereafter further motion of the shuttle will result allowing the third from the bottom slide in hopper 30 to move into receiving area 75 occupied by slide 70 in Figure 2. Actuator 80 will now move the shuttle 48 back to the position shown in Figure 2 for the next operation. If sensor 78 detects the absence of a slide, the control assembly is notified and the process is halted until an operator either overrides the system or adds more slides to hopper 30. The sensor 78 may be an electrical or pneumatic switch located at the side of hopper 30 as shown as at the bottom looking up. It should be noted that the receiving areas 75, 76 and 77 of Figure 7 are separated from one another by abutments 83 and 84, respectively, which abutments are also shown in Figure 2 in or about the sensing area. Small switches activated by the slide may be employed in the receiving areas instead of in the hopper if desired. Figure 2 also shows the pneumatic actuator 46 operable to move lifter head 44 both upward to open a sleeve pocket and upward and away from the rotating drum 40 as the sleeve material 12 moves into a position to receive slides from shutter 48. A vacuum connection 90A is shown in Figure 2 which supplies the vacuum in lifter head 44. In Figure 3, which is a side view of Figure 1, the elements which have been previously provided with reference numerals will have the same reference numerals. In Figure 3 the roll of sleeve material 12 is shown mounted for free rotation on the upright member 15 and the sheet of sleeve material is fed from the roll 12 down around a guide roller 90 and then fed along the base 10 under the actuator 25, tongue member 20 and tongue pushers 22, 23 and 24, under the actuator 48 and a second guide roller 92 to one of the sides 94 of the rotatable drum 40 shown as a dashed line hexagon in Figure 3. The sheet of sleeve material will be brought up along the surface of side 94 and a vacuum, which will be better described in connection with Figure 11 is applied to the interior of the drum 40 so as to cause the sheet of material to be pressed against side 94. Thereafter, through a motor drive controlled by controller 55 and through a one-way clutch and gear 98, the drum 40 is rotated in a clockwise direction thereby drawing the sheet of sleeve material into a position lying directly under the lifter head 44. Referring for a moment to Figure 9, a sheet of sleeve material is shown in more detail. In Figure 9, the material is shown to comprise a first or base piece of material such as plastic 100 having a second piece 101 atop thereof and sealed as by heat to the base continuously along areas such as shown as lines 105, 106, 107 and 108. The upper sheet material 101 is also sealed to the lower sheet 100 along lines such as shown by dashed lines 110 and 111. While two separate sheets have been shown in Figure 9, the upper sheet 100 and the second sheet 101 may be the same piece of material folded over on itself. As thus described so far, this would form a plurality of closed rectangular areas on the sleeve material. The upper material 101 is then cut along lines such as shown by reference numerals 115, 116, 117, 118, 119 and 120 so as to provide an access to the interior of the rectangles thus formed by the heat sealing. It is preferred that only the upper surface 101 be cut so as to provide a better container for the slides but some manufacturers may prefer to cut through both the sheets 100 and 101 for ease in manufacture, and such arrangement is acceptable for use with the present invention. As seen, the sleeve material on roll 12 will consist of a plurality of rows of pockets each consisting of three pockets. While three pockets are shown in connection with Figure 9, it should be understood that any number of pockets could be used, and there is no intention to limit the present disclosure to the use of three pockets per row. There is an advantage which accrues to the use of three pockets, however, in that the size of the slides is normally two inches by two inches and thus three slides side-by-side occupy a length that is approximately six inches. Two of these rows therefore form an area approximately six inches by four inches and after the slides have been injected into the pockets, they may be cut or folded into combinations approximately four inches by six inches so as to accommodate the standard size envelopes used to house photographic positives that are four by six inches in size. This enables ease in packaging and mailing without having to convert to specialized packages. Referring once again to Figure 2, it is seen that the drum 40 contains a plurality of small holes such as identified by reference numerals 120 in the outer surface thereof. As will be explained below, a vacuum is applied to the interior of drum 40 which operates through the holes 120 to pull the lower surface 100 of the sleeve material against one of the sides of the drum. Thereafter as the drum rotates, the sleeve material is pulled along until it reaches a position where no vacuum is applied and it is thereafter released. During the course of its travel it passes underneath the head 44 where the head 44 is lowered and a vacuum applied so as to pull the upper surface 101 of the sleeve material upwardly a slight distance thereby opening the pocket and allowing the slides such as 70, 71 and 72 to be pushed into these pockets by the tongue pushers 22, 23 and 24. As seen in Figure 3, after the slides have been entered into the pockets on the sleeve material, the sleeve material exits the system under the force of gravity and is shown at the right of Figure 3 extending downwardly to be cut or collected as desired. A more detailed view of the lifter head 44 can be found in Figure 5. In Figure 5 the lifter head 44 is shown in two positions, the solid line position being the position in which it holds the plastic material open for insertion of the slides. After the slides have been inserted, a pneumatic actuator shown in solid lines by reference numeral 46 operates through a linkage consisting of member 128 connected to a second actuator 130 which contains a piston 132 connected to the head 44 at a pivot point 134. There may be a third position (not shown) where the lifter head is lower than shown by solid line position 44 and is in contact with the sleeve material. This position is used to assure that the lifter head 44 will in fact capture the upper material of the pocket. After touching and capturing the upper material, actuator 130 is actuated and piston 132 raises the upper material slightly to open the pocket. After filling the pocket, actuator 46 is then actuated. When actuator 46 is energized by pneumatic pressure from pneumatic controller 52, member 128 will be moved upwardly to the position shown by dashed line 128' and actuator 130 will be moved to a position shown by dashed line 130'. This causes the piston 132 to occupy a position shown by dashed line 132' and it is seen that pivot point 134 is now moved to a point 134' which causes rotation of lifter head 44 around a pivot 138 to a position shown as dashed line 44'. During this motion, the vacuum is overcome and the upper sheet of material released to close the pocket. The lifter head 44 will then be out of contact with the sheet material thereby allowing the drum 40 to rotate another set of pockets into position. Head 44 will then again be lowered to contact position (not shown) and the process is repeated. Further details of the shuttle actuator are seen in Figures 6 and 6a. In Figure 6, the shuttle 48 is shown in dashed lines connected by a connection shown as cross-hatched area 142 to a first pneumatic actuator 144 having a piston 146. Actuator 144 is also shown connected to a second actuator 150 having a piston 152 bearing against a vertically extending abutment 154 connected to actuator 144. Actuator 150 in turn is connected to a third actuator 160 having a piston 162 which bears against a vertical abutment 164 connected to actuator 150 and to actuator 144. Actuator 160 is guided by a support member 168 to guide it in motion to the right and left. When all of the actuators are deactuated, i.e. all retracted to the left, the shuttle 48 will occupy the position shown in Figure 6a which corresponds to the position shown in Figure 2. In order to have the shuttle 48 move under the hopper 30 and receive the slides one at a time, actuator 144 is first actuated by a signal from sensor 78 and the controller 55 operates through the pneumatic actuator 144 to push the piston 146 to the right and thus carry the shuttle 48 to a first position determined by the length of piston 146. This will then lie in a position to receive a first of the slides, i.e. slide 170 of Figure 7, into area 77. When this has been accomplished, switch 78 signals the controller 55 that another slide is ready and actuation of actuator 150 results which moves piston 152 to the right thereby carrying actuator 144 and shuttle 48 a further distance to the right determined by the length of piston 152. This will position area 76 of Figure 7 under the hopper 30 and will allow a second slide, i.e. slide 172, to fall into the area 76. Thereafter switch 78 signals controller 55 that another slide is ready and actuation of actuator 160 results which causes piston 162 to move to the right carrying with it actuator 150 and actuator 144 thus moving shuttle 48 a further distance to the right determined by the length of piston 162 sufficient to bring area 75 in Figure 7 underneath the hopper 30 and allow a third slide, i.e. slide 174, to drop into the area 75. Thereafter the pneumatic actuators are caused to reverse and the shuttle 48 moves back into the position such as is shown in Figure 2 with the three slides now in position for insertion into the pockets when called for. Figure 4 shows further detail of rotatable drum 40 of Figures 1, 2 and 3. In Figure 4, the drum 40 is again shown as a hexagon and the sleeve material 12 is shown, as with Figure 3, passing under guide 92 and onto the surface 94. Drum 40 has a plurality of partitions extending from the central hub 170 thereof outwardly to the edges of the hexagon by walls 172. This divides the interior of the drum into six compartments of roughly triangular shape. The ends of the drum are sealed but, as better seen in Figure 11, a plurality of holes 178 are formed in one end leading to each of the triangular chambers. An end member or manifold 190 is seen in Figure 11, as approximately semi-circular in configuration and contains an aperture 192 large enough only to uncover two of the end holes 178, i.e. the two leading to chambers in the upper left and upper portions of drum 40 in Figure 4. The manifold 190 fits over the end of drum 140 around the central shaft and a pneumatic connection to the manifold 190 is shown by reference numeral 195 which applies a vacuum to the interior of the manifold 190 which can only escape through the opening 192. Since this is only applied to two of the apertures 178, it is only those two triangular volumes of the rotatable member 40 that are exposed to the vacuum. Thus, there will be a pressure exerted on the sleeve material 12 against surface 94 and against a surface 198 in Figure 4, but no pressure applied to surfaces 200, 202, 204 or 206. Thus, the underside of the sleeve material 12 will be held against surfaces 94 and 198, but not against the others. The lifter head 44 has a substantially square interior to which a vacuum is applied through a port 208 from the connection shown as 90A in Figure 2. This vacuum applies itself through apertures such as 212 in the head member 44 so as to pull the upper sheet member 101 away from the lower sheet member 100 to form a pocket as seen in Figure 4. After this pocket is opened, the slides which are shown in Figure 4 as with reference numeral 70, 71 and 72 are pushed to the right by the tongue pushers shown in Figure 4 by reference numerals 22, 23 and 24. The slides therefore enter the area between sheet 101 and 100 and thereafter the tongue members 22, 23 and 24 are withdrawn to the left in Figure 4. Head 44 is now rotated upwardly as described in connection with Figure 5 away from the now-filled pocket in sleeve member 12 and drum 40 can now be rotated in a clockwise direction so that the filled pockets will move to a position shown by surface 200 where the vacuum is released from the interior chamber of the drum 40. Now, under the pull of gravity, the sleeve will be lowered to a receiving station not shown. Figure 8 shows a more detailed cross sectional view of the tongue actuator 20 wherein it is seen that the pusher tongues 22, 23 and 24 are guided in their movement to the right in Figure 3 by two guide members 220 and 230 fastened together by bolts 233 so as to form rectangular slots for the tongue pushers 22, 23 and 24 to slide in. Finally referring to Figure 10, a second side view of the apparatus is shown similar to that in Figure 3, but in Figure 10, a slide mounter apparatus 240 which may be the slide mounter Model SA101 manufactured and sold by Pakon, Inc. is shown connected to the present invention as might be the case in actual practice. The mounter operates to mount slides in their cardboard or plastic containers and produce them as an output at a channel 242 which is shown leading to a slide chute 244 and into a feed hopper 246 shaped to receive the output of mounter 240 and seen to be in slightly different form than that of hopper 30 in Figure 3. The remainder of the apparatus in Figure 10 is like that shown in Figure 3 and will not be furthered described. It is therefore seen that I have provided a novel and unique method for packaging slides into plastic sleeves which is both economical and simple in its construction and provides inexpensive, light-weight and easy-to-view containers. Many obvious modifications will occur to those skilled in the art, as for example the drive mechanisms, while shown to be pneumatic could be mechanical and the various forms assumed by the various parts, such as the hexagonal shape for the drum, could be in other shapes, or the mounting mechanisms could all be done in other various ways found in the art. Accordingly, I do not wish to be limited to the specific disclosures used in connection with the preferred embodiments. I intend only to be limited by the following claims.

Claims: An apparatus for inserting mounted photographic slides into sleeve means (12) which has first and second portions of material fastened together to form a plurality of spaced pockets, the apparatus comprising a rotatable member (40), drive means (55,98) for rotating the rotatable member, first and second force producing means (178,190,195;40) for pulling the first and second portions, respectively, to open a first pocket, and inserting means (20,30,48) operable when the first pocket is open to insert one of the slides into the first pocket, characterized in that: the rotatable member (40) has a plurality of sides; the drive means (55,98) are operable to rotate said member (40) from a first position to a second position and to a third position; the first force producing means (178,190,195) is connected to said rotatable member (40) to produce a force adjacent a first side when the first side is in the first position, the force operable to pull the first portion of material of said sleeve means (12) against the first side so as to pull the plurality of pockets so that a first pocket is brought to the second position as the rotatable member (40) rotates; the second force producing means (44) is mounted adjacent the second position operable when the first side and the first pocket have reached the second position to pull the second portion of material away from the first portion of material so as to open the first pocket; and the inserting means (20,30,48) is operable when the first pocket is open to insert a photographic slide into the first pocket, the second force producing means (44) thereafter releasing the second portion of material to close the pocket on the slide and the drive means thereafter rotating the rotatable member (40) to pull the plurality of pockets so that the first pocket is brought to the third position where the first force producing means is released so that the first pocket is removable from the rotatable member (40). Apparatus according to Claim 1 wherein the first and second force producing means are first and second vacuum producing means, respectively. Apparatus according to Claim 2 wherein the second portion of material is translucent plastic to allow viewing of the slides in the pockets. Apparatus according to Claim 3 wherein the sleeve means (12) is an elongated sheet, and the first and second portions of material provide the plurality of spaced pockets, the rotatable member (40) operating to pull the sleeve means (12) continuously so that successive pockets are moved by the rotatable member (40) to the first position for attraction by the first vacuum producing means, to the second position for opening and filling the pockets and to the third position for releasing the filled pockets. Apparatus according to Claim 4 wherein the inserting means includes: a hopper (30) for receiving a plurality of slides; a reciprocal member (48) having a receiving area and movable from a first position to a second position, the receiving area of the reciprocal member (48) in the second position receiving a slide from the hopper (30), the reciprocal member (48) then returning with the slide to the first position; and a tongue member (20) having a pusher operable when the reciprocal member (48) is in the first position to push the slide from the receiving area into the opened pocket of the sleeve each time the rotatable member (40) is in the second position and the second vacuum producing means (44) has opened the pocket. Apparatus according to Claim 5 wherein the pockets on the sleeve means (12) are at least three abreast and the reciprocal member (48) has at least three receiving areas to receive at least three slides from the hopper (30) and the tongue member (20) has at least three pushers (22-24) to push the slides into the pockets simultaneously. Apparatus according to Claim 2 or 5 further including control means (55) operable to control the rotation of the rotatable member (40), to control the operation of the first and second vacuum producing means (178,190,195,44), to control the inserting means (20,30,48), to produce a timed sequence for rotating the rotatable member (40), opening the pocket, inserting the slide into the pocket, releasing the vacuums and rotating the filled pocket to the third position. Apparatus according to Claim 4 or 6 wherein the sleeve means (12) is mounted on a roll and is drawn from the roll by the rotating of the rotatable member (40). Apparatus according to Claim 5 further including switch means (78) mounted proximate said hopper (30) for sensing the existence of a slide at the bottom thereof and controlling the reciprocal member (48) accordingly.

Inventors: EDWARDS DONALD L, LAURIN DALE E, TRUC JAMES A, EDWARDS, DONALD L., LAURIN, DALE E., TRUC, JAMES A.
Applicants: PAKON INC, PAKON INC.
Application year: 1988
Main classification: G03D15
IPC codes: B65B43, B65B5, G03D15