A device for bending leaflets and transferring them into boxes

Abstract: The disclosed device comprises a transfer head (12) provided with tapering end portions (15) that can be elastically opened wide and cooperate with preforming edges (16) and forming elements (17) rotatably supported in a bending station (6) to fold over the side flaps (5b) of a leaflet (5) being worked. The head picks up the bent leaflet (5) from the bending station (6) to transfer it into a box-shaped casing (25). Stopping of the transfer head (12) stroke in the bending station (6), as well as positioning of the tapering end portions (15) can be adjusted depending on the type of paper of which the leaflet (5) is made.

Description: The present invention relates to a device for bending and transferring leaflets into box-shaped casings, of the type comprising a bending station, feed means for transferring at least one leaflet to the bending station, a transfer head movable with a reciprocating motion between a first operating position in which it is spaced apart from the bending station and in alignment therewith, ad a second operating position in which it acts on the leaflet arranged in the bending station, said transfer head having a base surface facing the bending station and at least one tapering end portion disposed perimetrically relative to the base surface, bending means operating in said bending station to fold back, in cooperation with the grip and transfer head, at least one side flap of the leaflet projecting from said end portion, and transfer means to transfer the bent leaflet from the bending station to a box-shaped casing located in a laying-down station. The invention is particularly conceived for employment on automated apparatuses for packaging compact discs into respective box-shaped protection casings. It is known that in the compact disc production field and other similar fields, discs are provided to be packaged in appropriate cases, generally of transparent plastic material, essentially comprised of a box-shaped casing of quadrangular configuration, open on one side thereof, in which a so-called tray defining an holding housing for one compact disc is engaged. Also hinged on one side border of the box-shaped casing is a closing element. In the progress of the packaging process, a leaflet generally carrying information related to the music piece or other data recorded on the compact disc is generally provided to be inserted into the holding casing before introduction of the tray. This leaflet essentially has a quadrangular flat configuration the two opposite side flaps of which are bent at an angle of 90° so as to completely cover corresponding side walls of the holding casing. Bending of the leaflet side flaps generally relies on an appropriate device with which the disc packaging apparatus is equipped. In European Patent No. 725 006 in the name of the same Applicant, a bending device is described which is essentially comprised of a transfer head and a countermould between which a leaflet to be bent is interposed. When the transfer head is lowered so as to enter the counter-mould, bending of the leaflet side flaps is automatically caused. The leaflet is then picked up from the counter-mould upon the action of the transfer head, to be subsequently introduced into the box-shaped casing arranged at a laying-down station disposed in side by side relationship with the bending station. It has been however found that employment of devices of the above type may give rise to some operating drawbacks, above all when, as it often happens, the typology of the used leaflets is submitted to changes. In particular, a correct execution of the bending operation is greatly affected by the type of paper forming the leaflet and the thickness thereof, as well as by the presence or not of possible die-cuttings provided on the leaflet in order to facilitate bending of same at the desired points. In addition, even when die-cut leaflets are employed, it has been found that immediately after bending, the leaflet flaps, due to the material elasticity, have a tendency to take an orientation coplanar with the base portion of the leaflet again. Under this situation, spontaneous disengagement of the leaflet from the holding casing may happen, before introduction of the tray is completed. The above drawbacks have been partially solved by another known bending device described in US Patent No. 4,685,277. The preamble of claim 1 is based on this prior art. In accordance with this device, in the bending station the leaflet is essentially held tight between a base block and a transfer head which in plan have the same configuration as the base portion of the leaflet. The leaflet held tight between these two components projects externally thereof by its side borders that are to be bent. Two rollers are caused to run along two opposite side walls of the base block, said rollers being elastically urged against the base block thereby causing bending of the side flaps about tapering end portions defining respective perimetric edges of the transfer head. The tapering end portions of the transfer head have an oblique orientation converging away from the base block, so that bending of the flaps upon the action of said rollers takes place at an angle greater than 90°. In more detail, conformation of the end portions of the transfer head is such calculated that the bent flaps have a tendency to take the required 90° orientation relative to the base portion of the leaflet, by effect of spring back of the material. With the aid of elements in the form of suction cups associated with the transfer head, the bent leaflet is then removed from the base block to be inserted into the holding casing of the disc case. Devices of this type as well however, give rise to some difficulties when they are to be set up, if employment of leaflets of different typologies is involved. Actually, the bending action imposed to flaps may be appropriate for some types of paper, light papers for example, but unsuitable when heavier papers or papers of different typology are involved. In addition, when some types of papers are employed, it may happen that bending of the side flaps is maintained at an angle greater than 90° also after spring back of the material, which will make disengagement of the leaflet from the transfer head and correct introduction of the tray into the box-shaped casing of the disc case, problematic. It has been also found that the action carried out by rollers does not always enable a sufficiently net and precise bending, above all when leaflets of rather heavy paper which have not been die-cut are employed. The main object of the present invention is substantially to solve the problems of the known art, by providing a device capable of operating in an efficient and reliable manner independently of the typology of the employed leaflets and the presence or not of die cuttings thereon. The foregoing and further objects that will become more apparent in the progress of the present description are substantially achieved by a device for bending and transferring leaflets into box-shaped casings, characterized in that said bending means comprises at least one forming element rotatably engaged in the bending station and having at least one coupling seating extending parallelly to a rotation axis of the forming element, in alignment with said tapering end portion, for engagement with said end portion by folding over the leaflet flap around said end portion when the head is brought to said second operating position. Further features and advantages will be best understood from the detailed description of a preferred but non-exclusive embodiment of a device for bending and transferring leaflets into box-shaped casings, in accordance with the present invention, given hereinafter by way of non-limiting example, with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of a bending and transferring device in accordance with the invention, mounted on an apparatus for packaging compact discs which is only partly shown; Fig. 2 is a cross-sectional view of a bending station during a preforming step of the leaflet; Fig. 3 is a fragmentary view of the bending station shown in Fig. 2, during an operating step in which bending of the leaflet is completed; Fig. 4 shows a transfer head during an operating step in which a bent leaflet is about to be introduced into a box-shaped casing; fig. 5 is a view similar to the one in fig. 4, during an operating step in which introduction of the leaflet into the box-shaped casing is completed; Fig. 6 is a side view of a detail relating to the transfer head employed in the device in reference, showing possibilities of adjustment for adaptation to different types of paper. With reference to the accompanying drawings, a device for bending and transferring leaflets into box-shaped casings in accordance with the present invention has been generally identified by reference numeral 1. Device 1 is associated with an apparatus 2 for packaging compact discs into disc cases generally denoted by 3 in Fig. 1, that are caused to move forward according to a step-by-step movement, along a packaging line 4. Apparatus 2 is not further described in detail in that it is known per se and not of importance to the ends of the present invention. A detailed description of this apparatus is given in the European Patent No. 725 006 in the name of the same Applicant. Device 1 operates in synchronism with the forward movement of cases 3 along a packaging line 4 for introduction of a leaflet 5 into each case 3, which leaflet has a base portion 5a and opposite side flaps 5b bent at 90° relative to the base portion 5a. To this end, the device 1 comprises a bending station 6 disposed in side by side relationship with the packaging line 4 and interlocked to feed means 7 carrying out positioning of the individual leaflets 5 thereinto after picking them up from a feeding magazine 8. In the embodiment shown in Fig. 1, the feed means essentially comprises a belt conveyor 9 terminating at the bending station 6 and a handling device equipped with an oscillating or rocking arm 10 that, with the aid of grip means in the form of a suction cup 10a picks up the individual leaflets 5 from the feeding magazine 8 for laying them down on the belt conveyor 9. A possible auxiliary handling device not shown in the drawings being feasible in a manner known per se, can be arranged for carrying out transfer of the individual leaflets from the belt conveyor 9 to the bending station 6. Alternatively, leaflet transferring can be executed directly by the belt conveyor 9 itself. Leaflet 5 laid down in the folding station 6 is maintained in engagement on one or more support housings 11. Said support housings preferably act on leaflet regions corresponding to the leaflet side flaps 5b to support the leaflet itself in an interposition condition between the movable transfer head 12 and the bending means 13 arranged to cooperate with the transfer head 12 to fold over the side flaps 5b of leaflet 5. Leaflet 5 positioning is shown in chain line in Fig. 2. The transfer head 12 is provided with a reciprocating motion, preferably in a vertical direction, between a first operating position in which, as shown in chain line in Fig. 2, it is spaced apart from the bending station 6, in alignment therewith, and a second operating position in which, as shown in solid line in Figs. 2 and 3, operates on leaflet 5 so as to fold over the side flaps 5b thereof in cooperation with the bending means 13. As viewed from the accompanying drawings, the transfer head 12 has a base surface 14 facing the bending station 6 and arranged to act on the base portion 5a of leaflet 5, as well as at least one tapering end portion 15 disposed peripherally relative to the base surface 14, along a side of the latter. More specifically, two tapering end portions 15 are provided which are disposed laterally on opposite sides relative to the base surface 14. The tapering end portions 15 have an orientation diverging obliquely from the movement direction of the transfer head 12 and project from the base surface 14 in the movement direction of the head itself towards the second operating position. In addition, as clearly shown in Fig. 2, the tapering end portions 15 are mutually spaced apart by a distance lower than the linear extension of leaflet 5. Therefore, when leaflet 5 is positioned on the support housings 11 arranged in the bending station 6, the leaflet side flaps 5b project laterally relative to the tapering end portions 15 of the transfer head 12. During its translation from the first to the second operating position, the transfer head 12 brings the extremities of the tapering end portions 15 into contact with leaflet 5. This contact takes place along the bending lines according to which the side flaps 5b of leaflet 5 will be then folded over. During this step, suction-cup elements or similar suction means converging on the base surface 14 of the transfer head 12 and not shown as known per se and conventional, carry out adhesion of the base portion 5a of leaflet 5, against the base surface 14. Projection of the tapering end portions 15 relative to the base surface 14 forces leaflet 5, under this circumstance, to take an arch-shaped configuration, as can be viewed from Figs. 2, 3 and 4. As lowering of the transfer head 12 towards the second operating position goes on, the tapering end portions 15 interact with the bending means 13 to cause bending of the side flaps 5b. According to a preferential feature of the invention, the bending means comprises at least one preforming edge 16, and more specifically a pair of preforming edges 16, each of which is arranged to cooperate with the corresponding tapering end portion 15 to bend the leaflet side flap 5b substantially at an angle of 90°. To this end, the relative positioning between each preforming edge 16 and the corresponding tapering end portion 15 is such arranged that a gauged passage of a width substantially corresponding to or slightly greater than the leaflet 5 thickness is defined between them. Preferably, as clearly shown in Figs. 2 and 3, each preforming edge 16 at its upper part defines one of the support housings 11. Therefore, cooperation between the tapering end portions 15 and the preforming edges 16 occurs as soon as the tapering portions go down to a lower level than the lying plane of leaflet 5 on the support housings 11. Arranged adjacent to the preforming edges 16 are respective forming elements 17 each intended for cooperation with one of the tapering end portions 15 when head 12 reaches the second operating position. To this end, each forming element 17 is provided with at least one coupling seating 18 extending in vertical alignment with the tapering end portion 15, so that the tapering end portion engages the coupling seating 18 when the transfer head 12 is about to reach its second operating position. In particular, each forming element 17 is essentially defined by a cylindrical body rotatably engaged in the bending station 6 according to its geometric rotation axis, disposed at a position laterally spaced away from the transfer head 12 relative to the extremity of the tapering end portion 15. The coupling seating 18 is advantageously defined by a groove of rectangular profile extending along a generatrix of the cylindrical body 17. In particular, as viewed from Figs. 2 and 3, the coupling seating 18 has a first locating edge 18a adapted to act in interference relationship on an inner side 15a of the tapering end portion 15 when, following descent of the transfer head 12 to the second operating position, the end portion 15 enters groove 18. Interference between the first locating edge 18a and the inner side 15a of the tapering end portion 15 causes the forming element 17, following a subsequent slight lowering of head 12 towards the second operating position, to be forced to rotate about its own axis. Due to the angular rotation carried out by the forming element 17, a second locating edge 18b of the groove forming the coupling seating 18 is brought into abutment relationship against an outer side 15b of the tapering end portion 15, on the laterally opposite side relative to the first locating edge 18a, thereby causing a net bending of the side flap 5b about the extremity of the tapering end portion 15. The angular rotation of each forming element 17 takes place against the action of at least one torsion spring 19 or equivalent return spring means that, in cooperation with stop pegs 19a, 19b located on the forming element 17 and a fixed portion of the bending station 6 respectively, carry out new positioning of the coupling seating 18 in alignment with the extremity of the tapering end portion 15 when the transfer head 12 is moved away again from the second operating position. Movement of the transfer head 12 on reaching of the second operating position is stopped by one or more stop elements 20 engaged in the bending station 6 and acting in abutment relationship against the base surface 14 of the transfer head itself. Associated with the stop elements 20 is first adjustment means 21 by which a careful adjustment of the limit stroke of the transfer head 12 in the second operating position can be carried out. In accordance with this adjustment means 21, it is essentially provided that each stop means 20 be fastened to an end of a screw-threaded rod 22 operatively engaged in a screw-threaded hole 22a arranged in the bending station. A locking nut 22b enables a steady fastening of the respective stop element 20 to the desired position. Upon intervening on the stop elements 21, the location at which the transfer head 12 is stopped in the second operating position and, as a result, the amount of the angular rotation imparted to the forming elements 17, can be advantageously adapted to the typology and thickness of the paper forming leaflet 5. Therefore, stopping of the transfer head 12 in the second operating position can be advantageously adjusted in such a manner that, independently of the type and thickness of the paper forming leaflet 5, the side flaps 5b are folded over at an angle greater than 90°, so that said flaps, by effect of the material elasticity, spontaneously take an orientation of substantially 90° relative to the base portion 5a when, following the transfer head 12 return to the first operating position, the tapering end portions 15 disengage from the bending means 13. Further provided in the device in reference is the presence of transfer means that carries out transferring of the bent leaflet 5 from the bending station 6 to a laying-down station 23 disposed along the packaging line 4. Preferably, this transferring means consists of the same transfer head 12, the latter being mounted on a handling arm 24 carrying out translation thereof in a horizontal direction or in any case perpendicularly to the movement direction of the first and second operating positions. In more detail, upon command of the handling arm 24 (only partly shown in Fig. 1 in that it can be made in a manner known per se and conventional), the transfer head 12 is brought from the first operating position to a third operating position in which, as shown in chain line in Fig. 4, it is disposed in alignment with a box-shaped casing 25 being part of a disc case 3, spaced apart from said box-shaped casing itself. Once the transfer head 12 has reached its third operating position, it performs a vertical stroke to a fourth operating position in which leaflet 5 in engagement therewith is inserted into the box-shaped casing 25. In accordance with a further feature of the present invention, each of the tapering end portions 15 is formed on a plate-like element 26 oscillatably engaged with a corresponding side of the transfer head 12. In more detail, the plate-like element 26 has, on an opposite side from the tapering end portion 15, an end edge 26a operatively engaged in a constraint housing defined between the corresponding side wall of the transfer head 12 and a locating block 27 fastened to said head. One or more springs or equivalent counter spring means 28 act between locating elements 29 fixedly carried by the transfer head 12 and the plate-like element 26 to keep the latter laterally urged against the transfer head. In this way, the locating elements 26 and, consequently, the end portions 15 are laterally movable relative to the base surface 14 of the transfer head 12, against the action of counter springs 28. As clearly viewed from comparison of Figs. 4 and 5, when the transfer head 12 comes close to the fourth operating position, the tapering end portions 15 come into abutment relationship against a bottom wall 25a of the box-shaped casing 25, while keeping slightly spaced apart from the side walls 25b of the casing itself. By a slight further forward movement of the transfer head 12 to the fourth operating position, the end portions 15 are forced to slightly open wide from the transfer head 12 by rotating about the constraint points of the end edges 26a of the plate-like elements 26 and sliding on the bottom wall 25a of casing 25. In this manner the side flaps 5b of leaflet 5 are brought against the side walls 25b of casing 25. Meanwhile, action of the suction means associated with the transfer head 12 is stopped so that the base portion 5a of leaflet 5, that up to now had kept an arch-shaped configuration, is extended in coplanar relationship with the bottom wall. During the starting step for moving the transfer head 12 up towards the third operating position, the tapering end portions 15 will be called back to their initial position by counter springs 28. Thus assurance of a complete disengagement of leaflet 5 from the transfer head 12 is acquired, and the risk that the tapering end portions 15 would interfere with the side flaps 5b, should the latter remain bent at an angle slightly greater than 90°, is also eliminated. Advantageously, positioning of the tapering end portions 15 relative to the transfer head 12 can be adjusted, depending on the type and thickness of the paper forming leaflet 5 for example, as well as depending on the sizes of the box-shaped casing. To this end, as clearly shown in Fig. 6, each of the locating blocks 27 can be positioned longitudinally relative to the transfer head 12, said block being removably fastened to said head by screw-threaded locking elements 30 operating through respective elongated holes 30a arranged in the locating elements. Rest housings 27a for the end edges 26a of the plate-like elements 26 are defined by inclined surfaces, so that following a longitudinal displacement of the locating block 27, a displacement of the plate-like element 26 in its lying plane is obtained, which will bring the tapering end portion 15 to project to a more or less important degree relative to the base surface of the transfer head 12, thereby also adjusting width of the gauged passage defined with the respective preforming edge 16. Auxiliary elongated slide holes 31 arranged in each plate-like element 26 enable guided sliding of said element relative to the locating elements 29 carrying counter springs 28. The present invention achieves the intended purposes. The device in reference in fact has an excellent operating adaptability to any type of paper employed in making leaflets 5. Structure and operation of the forming elements 17 is such conceived that formation of perfect folds are ensured even in the absence of die cuttings on the leaflets being worked. In addition, mobility of the tapering end portions 15 ensures release of leaflet 5 into the casing 25, as well as positioning of the bent flaps 5b against the side walls 25b, also compensating for wide size tolerances in the casing itself.

Claims: A device for bending and transferring leaflets into box-shaped casings, comprising: a bending station (6), feed means (7) for transferring at least one leaflet (5) to the bending station (6), a transfer head (12) movable with a reciprocating motion between a first operating position in which it is spaced apart from the bending station (6) and in alignment therewith, and a second operating position in which it acts on the leaflet (5) arranged in the bending station (6), said transfer head having a base surface (14) facing the bending station (6) and at least one tapering end portion (15) disposed perimetrically relative to the base surface, bending means (13) operating in said bending station (6) to fold back, in cooperation with the transfer head (12), at least one side flap (5b) of the leaflet projecting from said end portion (15), transfer means to transfer the bent leaflet (5) from the bending station (6) to a box-shaped casing located in a laying-down station (23), characterized in that said bending means (13) comprises at least one forming element (17) rotatably engaged in the bending station (6) and having at least one coupling seating (18) extending parallelly to a rotation axis of the forming element, in alignment with said tapering end portion (15), for engagement with said end portion (15) by folding over the leaflet flap (5b) around said end portion when the head (12) is brought to said second operating position. A device as claimed in claim 1, characterized in that said forming element (17) comprises a cylindrical body engaged in the folding station (6) in a rotatable manner according to its geometrical axis and provided with at least one groove extending along a generatrix thereof to define said coupling seating (18). A device as claimed in claim 2, characterized in that said coupling seating (18) has a first locating edge (18a) acting by interference on an inner side (15a) of said tapering end portion (15) to cause an angular rotation of the forming element (17) when the transfer head (12) comes to the second operating position, and a second locating edge (18b) acting against an outer side (15b) of the tapering end portion (15) on the laterally opposite side relative to said first locating edge (18a), following a rotation carried out by the forming element (17). A device as claimed in claim 1, characterized in that it further comprises return spring means (19) acting against rotation of the forming element (17). A device as claimed in claim 1, characterized in that said bending means (13) further comprises at least one preforming edge (16) extending close to the forming element (17) and arranged to cooperate with said tapering end portion (15) to bend the leaflet flap (5b) before the end portion comes into engagement with the forming element (17). A device as claimed in claim 5, characterized in that said at least one preforming edge defines a support housing (11) for supporting the leaflet (5) at an interposition location between the transfer head (12) disposed in the first operating position and said bending means (13). A device as claimed in claim 1, further comprising at least one stop element (20) operating on the transfer head (12) to stop moving forward of said head to the second operating position, adjustment means (21) being associated with said stop element (20) to adjust the stop location of the transfer head (12) in the second operating position. A device as claimed in claim 1, characterized in that said tapering end portion (15) projects from the base surface in the movement direction of the transfer head (12) towards the second operating position. A device as claimed in claim 8, characterized in that the tapering end portion (15) has an orientation diverging obliquely from the movement direction of the transfer head (12) between the first and second operating positions. A device as claimed in claim 8, characterized in that said tapering end portion (15) is formed on a plate-like element (26) removably in engagement with the transfer head (12). A device as claimed in claim 10, characterized in that the end portion (15) can be laterally moved away relative to the base surface (14) against the action of counter spring means (28). A device as claimed in claim 11, characterized in that said counter spring means (28) operates between locating elements (29) rigidly carried by the main portion of the transfer head and said plate-like element, the last-mentioned element being linked in an oscillatable manner to a side wall of the main portion itself. A device as claimed in claim 10, characterized in that it further comprises adjustment means to set positioning of the plate-like element (26) on the transfer head (12). A device as claimed in claim 13, characterized in that said adjustment means comprises at least one locating block (27) having an inclined abutment plane (27a) on which an end edge (26a) of the plate-like element (26) opposite to said tapering end portion (15) acts, said locating block (27) being adapted to be selectively positioned on said head in order to modify positioning of the tapering end portion (15). A device as claimed in claim 1, characterized in that said transferring means essentially consists of the transfer head (12), said head being movable perpendicularly to the movement direction between the first and second operating positions to transfer said leaflet (5) from the bending station (6) to a laying-down station (23). A device as claimed in claim 15, characterized in that in the laying-down station (23) the transfer head (12) is movable from a third operating position to a fourth operating position for laying down the bent leaflet (5) into a box-shaped casing (25).

Inventors: PEREGO LUCIANO, PEREGO, LUCIANO
Applicants: TAPEMATIC SPA, TAPEMATIC S.P.A.
Application year: 1997
Main classification: B65B25
IPC codes: B65B25