CAP SHEET FORMING APPARATUS

Abstract: A sheet insertion apparatus (10) for formation of a cap sheet for use with a palletizing load, the sheet insertion apparatus (10) having a conveyor assembly (30) with an infeed end (32) and a sheet delivery end (34). A bottom sheet dispenser (36) dispenses bottom sheets (42A) of material onto the conveyor assembly (30) proximate to the infeed end (32), and a cross sheet dispenser (38) dispenses cross sheets (42B) of material onto the conveyor assembly (30) downstream of the bottom sheet dispenser (36), the cross sheets (42B) overlapping a portion of the bottom sheets (42A). An embosser assembly (120) simultaneously embeds stitches in the bottom sheets (42A) and the cross sheets (42B) to form a cap sheet, the conveyor assembly (30) moving the cap sheet to a selected position.

Description: Description Cap Sheet Forming Apparatus Technical Field This invention relates generally to the field of materials handling, and more particularly, but not by way of limitation, to a cap sheet forming apparatus for forming and inserting cap sheets for a load of stacked material. Background Art Manufacturers of corrugated paper products, such as corrugated boxes, trays and flat corrugated sheets, typically arrange the product in relatively small bundles. The bundles are arranged in layers, or tiers, and the tiers are then stacked vertically to form a rather large "load" of the product for transportation to customers. The load is often banded together and stacked on a pallet to facilitate handling of the load. The conveyance, handling, banding and transportation of the loads on pallets can result in damage to the product if proper precautions are not taken. Thus, manufacturers have commonly placed one or more sheets of corrugated paper on the bottom and at times even on the top of the loads to protect the stacked loads of product from damage. These protective sheets are commonly referred to as "cap sheets." If the load is to be banded, these cap sheets are often placed in a crossed orientation so that the cap sheets overlap the upper and lower edges of the load to prevent the bands from damaging the edges of the load. The load forming process has been typically performed by an operator, either completely by hand or with the assistance of a semi-automatic load former which helps the operator to stack the tiers. In either case, it is common for the operator to lay down the cap sheet or sheets and then build the load on top thereof. If necessary, the operator can place an additional cap sheet or sheets on top of the load. There is a generally recognized trend in the corrugated industry toward fully automatic load formers which do not require an operator to form loads. These automatic machines require a means for inserting the cap sheets. Prior art devices use vacuum (suction) cups to pick up a cap sheet from a stack thereof and place it in the desired location. These devices utilize special cap sheets that must be specially produced by the manufacturer for the intended purpose. Of course, production of these special cap sheets costs the manufacturer in both material and lost production time. Prior art devices have limited capabilities for use of "scrap" corrugated sheets (i.e., left over sheets of various dimensions) and prove to be unreliable. Another drawback to these prior art devices is that such devices do not have the capability of forming various patterns with the cap sheets to accommodate the variable needs of the manufacturer. Thus, there is a need for an improved approach to formation and placement of cap sheets which overcomes the deficiencies of the prior art mentioned above. Disclosure of the Invention The present invention provides an apparatus and process for forming and inserting cap sheets for a load of corrugated paper sheets or the like. A sheet insertion apparatus includes a conveyor assembly extending substantially horizontally and having an infeed end and a sheet delivery end. A bottom sheet dispenser and a cross sheet dispenser are supported near the infeed end of the conveyor assembly with the cross sheet dispenser disposed downstream from the bottom sheet dispenser. The bottom sheet and the cross sheet are conveyed through an embossing assembly where lobed embossing rollers spike penetrate the sheets to interlock the sheets to maintain proper alignment and provide consistent placement of such sheets and consequently form a cap sheet. The formed cap sheet is conveyed for discharge from the conveyor assembly at the sheet delivery end. The conveyor assembly can be provided with a cap sheet stacker to lift the cap sheet to permit the disposition of another cap sheet, once formed, beneath the first cap sheet so that a double cap sheet can be assembled on the conveyor. The double cap sheet is then conveyed for discharge at the sheet delivery end of the conveyor. The sheet insertion apparatus can be provided a control means for controlling the several drive means of the bottom sheet dispenser, the cross sheet dispenser, the convey assembly, the embossing assembly to minimize operator control input. The objects, advantages and features of the present invention will be apparent from the following description when read in conjunction with the drawings and appended claims. Brief Description of the Drawings FIG. 1 is a side elevational view of a sheet insertion apparatus constructed in accordance with the present invention and shown in operational configuration with a load former and tie sheet assembly. FIG. 2 is another side elevational view of the sheet insertion apparatus of FIG. 1. FIG. 3 is a top plan view of the bottom sheet dispenser of FIG. 2. FIG. 4 is a side elevational view of the bottom sheet dispenser of FIG. 3. FIG. 5 is a top plan view of the cross sheet dispenser of FIG. 2. FIG. 6 is an elevational view of the cross sheet dispenser of FIG. 5. FIG. 7 is a top plan view of conveyor apparatus of FIG. 2. FIG. 8 is a side elevational view of the conveyor apparatus of FIG. 7. FIGS. 9 and 9A are elevational and end views, respectively, of one of the hold-down rolls of the sheet insertion apparatus of FIG. 2. FIGS. 10 and 10A are elevational and end views, respectively, of one of the sheet intermediate hold-down rolls of the sheet insertion apparatus of FIG. 2. FIGS. 11 and 11 A are elevational and end views, respectively, of one of the sheet embossing rolls of the sheet insertion apparatus of FIG. 2. FIGS. 12A through 12G illustrate possible bottom sheet and cross sheet combinations with the sheet insertion apparatus of FIG. 2. FIG. 13 illustrates a typical load on a cap sheet made by the present invention. FIG. 14 is a depiction of a typical spike penetration formed such as by the sheet embossing rolls of FIG. 11 and FIG. 11A. FIG. 15 is a diagrammatic depiction of the control and operation of the sheet insertion apparatus of FIG. 2. Best Mode for Carrying Out the Invention The present invention provides an apparatus for inserting cap sheets formed from scrap sheets of varying dimensions and for delivering the cap sheets in a desired pattern to a selected site, such as to a load former. Referring to the drawings in general, and more particularly to FIG. 1 , shown therein is a sheet insertion apparatus 10 constructed in accordance with the present invention. The sheet insertion apparatus 10 is depicted in operational alignment with a load former 12 the purpose of which is to form stacks of articles, such as corrugated board blanks 14, onto an elevator conveyor 16. Once stacked, the elevator conveyor 16 delivers the stack of blanks 14 to a conveyor 18. Load formers such as depicted in FIG. 1 are well known, and the present invention is not intended to be limited by the type of load former serviced by the sheet insertion apparatus 10. Although not forming a part of the present invention, as shown in FIG. 1, the load former 12 has a tie sheet assembly 20 of conventional construction the purpose of which being to deliver separator sheets via vacuum cup pickups to be placed between tiers of blanks 14. Such separator sheets are useful in maintaining the integrity of the stack of blanks 14 during transportation thereof. The sheet insertion apparatus 10 more clearly appears in FIG. 2 wherein the components thereof are shown. More directly, the sheet insertion apparatus 10 has a conveyor assembly 30 which extends substantially horizontally and has an infeed end 32 and a sheet delivery end 34. A bottom sheet dispenser 36 is disposed near the infeed end 32 of the conveyor assembly 30, and a cross sheet dispenser 38 is disposed in near proximity and downstream thereto. Preferably, the bottom sheet dispenser 36 and the cross sheet dispenser 38 are similarly constructed, and each is supported by a support stand 40 as shown. The bottom sheet dispenser 36 and the cross sheet dispenser 38 are disposed to hold a stack of sheets 42A and 42B, respectively, of various sizes and to deliver individual sheets onto the conveyor assembly 30 in the manner to be described below. FIGS. 3 and 4 will now be referenced as the bottom sheet dispenser 36 is described. The bottom sheet dispenser 36 has a pair of endless conveyor belts 50 supported by a pair of spatially separated support shafts 52, 54 rotatably supported by a frame 56. The shaft 54 is powered by a gear motor assembly 58. An upright frame 60 supported by the frame 56 in turn supports a side guide assembly 62 and a shingling assembly 64. The side guide assembly 62 has a first side guide 66 and a second side guide 68, both of which are slidingly supported by a pair of parallel slide rods 70. A threaded rod 72 extends between, and parallel to, the pair of slide rods 70 and supported by bearings for selective rotation. Each of the first and second side guides 66, 68 has a threaded bore through which the threaded rod 72 extends, and a rotational handle 74 is secured to one end of the threaded rod 72. The threaded rod 72 has threads of opposite pitch at one end from the other end so that rotation of the rotational handle 74 will move the first and second side guides 66, 68 in unison toward or away from each other in order to establish the distance therebetween and thereby set the side boundaries for the stack of sheets 42A. The shingling assembly 64 has a pair of travel carriages 76 slidably supported for movement up and down along the upright frame 60. A pair of threaded rods 78 are supported for rotation and are disposed parallel to the upright frame 60. A rotatable handle 80 is connected to one of the threaded rods 78, and a gear and chain arrangement (not shown) effects movement of the other threaded rod 78 so that these members are rotated in unison with rotation of the handle 80 to move the pair of travel carriages 76 in unison. A metering blade 82 is supported by the travel carriages 76 above the conveyor belts 50 and serves to restrict the passage of sheets 42 A from the stack of sheets 42 A onto the endless belts 50. The metering blade 82 is angularly disposed as shown to facilitate movement of the bottom sheet feeding from the stack of sheets 42 A. With the bottom sheet dispenser 36 preferably angularly disposed at about 30 degrees from horizontal above the conveyor assembly 30, the sheets fed from the stack of sheets 42 A have been found to pass singularly in procession beneath the metering blade 82 when properly adjusted to accommodate the thickness of the sheets of stack 42 A. Three photo eyes 84 A through 84C, depicted diagrammatically in FIGS. 3 and 4, are disposed in proximity to, and above, the output of the endless belts 50. These photo eyes 84A through 84C detect the position of a sheet of the stack of sheets 42A exiting from below the metering blade 82, the purpose of which will become clear below. Disposed at the outlet of the endless belts 50 immediately downstream to the metering blade 82 is a pinch roll assembly 86. The pinch roll assembly 86 comprises a plurality of top rollers 88 disposed on a journalled shaft 90, and a plurality of bottom rollers 92 disposed on a journalled shaft 94. A gear motor assembly 96 is provided to selectively power the shaft 94. Preferably, the top rollers 88 and the bottom rollers 92 are made of pliant material such as urethane and are adjustably mounted for variable pinch capability when rotated together. The pinch roll assembly 86 serves to propel the fed sheet 42 from the endless belts 50. Turning to FIGS. 5 and 6, shown therein is the cross sheet dispenser 38 which, as mentioned above, is similar in construction to that of the bottom sheet dispenser 36. Accordingly, the same numbers appearing above will be used to describe the cross sheet dispenser 38. The cross sheet dispenser 38 has a pair of endless conveyor belts 50 supported by a pair of spatially separated support shafts 52, 54 rotatably supported by a frame 56. The shafts 54 is powered by a gear motor assembly 58, and an upright frame 60 supported by the frame 56 supports a side guide assembly 62 and a shingling assembly 64. The side guide assembly 62 has a first side guide 66 and a second side guide 68, both of which are slidingly supported by a pair of parallel slide rods 70. A threaded rod 72 extends between and parallel to, the pair of slide rods 70 and is supported by bearings for selective rotation. Each of the first and second side guides 66, 68 has a threaded bore through which the threaded rod 72 extends, and a rotational handle 74 is secured to one end of the threaded rod 72. The rod 72 has threads of opposite pitch at one end from the other end so that rotation of the rotational handle 74 will move the first and second side guides 66, 68 in unison toward or away from each other in order to establish the distance therebetween and thereby set the side boundaries for the stack of sheets 42B. The shingling assembly 64 has a pair of travel carriages 76 slidably supported for movement up and down along the upright frame 60. A pair of tlireaded rods 78 are supported for rotation and are disposed parallel to the upright frame 60. A rotatable handle 80 is connected to one of the threaded rods 78, and a gear and chain arrangement (not shown) effects movement of the other threaded rod 78 so that these members are rotated in unison with rotation of the handle 80 to move the pair of travel carriages 76 in unison. A metering blade 82 is supported by the travel carriages 76 above the conveyor belts 50 and serves to restrict the passage of sheets from the stack of sheets 42B on the endless belts 50. The metering blade 82 is angularly disposed as shown to facilitate movement of the bottom sheet feeding from the stack of sheets 42B. With the bottom sheet dispenser 36 preferably angularly disposed at about 30 degrees from horizontal above the conveyor assembly 30, the sheets fed from the stack of sheets 42B have been found to pass singularly in procession beneath the metering blade 82 when properly adjusted to accommodate the thickness of the sheets 42B. A photo eye sensor 98, depicted diagrammatically in FIGS. 5 and 6, is disposed in proximity to, and above, the output of the endless belts 50. This photo eye sensor 98 detects the position of the sheet 42B exiting from below the metering blade 82. Disposed at the outlet of the endless belts 50 immediately downstream to the metering blade 82 is a pinch roll assembly 86. The pinch roll assembly 86 comprises a plurality of top rollers 88 disposed on a journalled shaft 90, and a plurality of bottom rollers 92 disposed on a journalled shaft 94. A gear motor assembly 96 is provided to selectively power the shaft 94. Preferably, the rollers 88, 92 are made of a pliant material such as urethane and are adjustably mounted for variable pinch capability when rotated together. The pinch roll assembly 86 serves to propel the fed sheet 42B from the endless belts 50. The conveyor assembly 30 will now be described with reference to FIGS. 2, 7, and 8. As shown therein, the conveyor assembly 30 comprises a plurality of spaced apart endless belts 100 supported to extend between a drive first shaft 102 and a driven second shaft 104 over appropriately disposed rollers 106 thereon. The drive first shaft 102 and the driven second shaft 104 are journalled for rotation on a support frame 108 as shown. A gear motor assembly 110 is provided to drive the first shaft 102 and to drive the second shaft 104 via chains and sprockets 1 11, thereby driving the endless belts 100. A pinch roller assembly 112 is supported by the support frame 108 at the sheet delivery end 34 of the conveyor assembly 30, the pinch roller assembly 112 having a plurality of pinch rollers 114 on a journalled shaft 116, with each of the pinch rollers 114 disposed in rotational cooperation with and in near proximity to, one of the endless belts 100 as shown. See also FIGS. 9 and 9A. Preferably, the pinch rollers 114 are made of a pliant material such as the zero crush rollers available from Universal Urethane Products of Toledo, Ohio. Supported by the frame 108 near a medial portion thereof is an embosser assembly 120 which has a gear driven, journalled upper shaft 122 supporting a plurality of pinch rollers 124. Preferably, the pinch rollers 124 are made of a pliant material such as the aforementioned zero crush rollers, each of the pinch rollers 124 disposed in rotational cooperation with, and in near proximity to, one of the belts 100 in the manner shown in FIGS. 10 and 10 A. Also supported by the shaft 122 are a plurality of multi-lobed embossing rollers 126 (best shown in FIGS. 11 and 11 A). As shown, each embossing roller 126 has three pointed lobes 127. The embosser assembly 120 also has a chain driven lower shaft 128 (the chain, not shown, is driven from the shaft 102 via the gear motor assembly 110) which supports a plurality of backup rollers 125 and a plurality of grooved rollers 130 that matingly align and interact with the multi-lobed embossing rollers 126 to receive the lobes 127 thereof, the perimeter of the grooved rollers serving to support the sheets 42 A and/or 42B. The upper shaft 122 and the lower shaft 128 are interconnected by a pair of spur gears (not shown) so that the upper shaft 122 is driven by the lower shaft 128. As the sheets 42A and/or 42B are conveyed by the conveyor assembly 30, the embossing rollers 126 and grooved rollers 130 interact to puncture the sheets via the lobes 127 to stitch together multiple sheets 42A, 42B passed therebetween, thereby maintaining proper alignment and providing reliable placement of the sheets. A series of photo eye sensors 132A-C, 134A-C, and 142A-C are additionally provided in the positions depicted in FIGS. 2 and 7 to detect the position of sheets during the passage of the sheets over the conveyor 30. the operation of which will become clear below. The conveyor assembly 30 further includes a cap sheet stacker 140 for lifting the cap sheet to allow advancement of a second cap sheet below the cap sheet stacker 140 so that a cap sheet can be lowered onto a second cap sheet to be simultaneously advanced. The cap sheet stacker 140 has several suction lifters 142 supported by, and communicating with, a laterally extending tube member 144 which is supported from an over frame (not separately designated) via a pair of air cylinders 146 (one shown in FIG. 2). A vacuum generator (not shown) .and a release valve (not shown) selectively draw and release vacuum pressure on the suction lifters 142. Having now reviewed a preferred construction of various aspects of the sheet insertion apparatus 10, the present discussion will now generally turn to a review of the operation of the sheet insertion apparatus 10 to form cap sheets as depicted diagrammatically in FIG. 15. Further construction details will also become clear in the discussion to follow. General reference to FIGS. 1-14 will be made in discussing the method of operation of the present invention depicted in FIG. 15. In particular, the bottom sheet dispenser 36 is adapted to carry a plurality of vertically stacked scrap material sheets 42 A (hereinafter bottom scrap sheets) on the drive belts 50, the bottom scrap sheets 42 A having a leading edge and a trailing edge such as identified at 148 and 150, respectively, in FIG. 12 A. The bottom sheet dispenser 36 sequentially advances each bottom scrap sheet 42A via the bottom sheet dispenser drive belts 50. The three pinch roll photo eyes 84A-C disposed near the output ends of the bottom sheet dispenser drive belts 50 detect the position of the bottom scrap sheet 42 A to indicate the proximity of the bottom scrap sheet 42 A to the bottom sheet pinch rollers 86 and subsequently send a corresponding signal to a programmable logic controller 150 or any such equivalent controller. The programmable logic controller 152 then sends a signal to the gear motor assembly 58 to effectuate control of the pinch roller assembly 86 for feeding sheets therethrough. The photo JO- eyes 84A-C thereby act in conjunction with the bottom sheet pinch roller assembly 86 to allow multiple sheets 42A to be dispensed, whereby the pinch rollers 86 deter the movement of the multiple sheets 42A to ensure that the sheets are lined up and are dispensed evenly. The bottom sheet dispenser 36 then advances the bottom scrap sheet 42A to the conveyor assembly 30 located below the pinch roller assembly 86 until the leading edge 148 of the bottom scrap sheet 42 A passes the bottom sheet lead edge photo eyes sensors 132A-C at which instance the bottom sheet lead edge photo eye sensors 132A-C signal to the programmable logic controller 152 to control the conveyor assembly 30 through a gear motor assembly 110 to allow for the placement of a subsequent sheet onto the bottom scrap sheet 42A. The cross sheet dispenser 38, adjacent to the bottom sheet dispenser 36 may then advance each cross scrap sheet 42B via the cross sheet dispenser drive belts 50, the cross scrap sheet 42B having a leading edge and a trailing edge such as identified at 154 and 156 in FIG. 12E. The cross sheet pinch roll photo eye 90 located before the cross sheet pinch roller assembly 86 indicates the position of the cross scrap sheet 42B to send a signal to the programmable logic controller 152 for effectuating control of the pinch roller assembly 86. The cross sheet pinch roller assembly 86 allows displacement of the cross scrap sheet 42B onto the conveyor assembly 30 atop the bottom scrap sheet 42A such that the cross scrap sheet 42B and the bottom scrap sheet 42 A advance together to the embosser assembly 120. The embosser assembly 120 spikes the bottom scrap sheet 42 A and the cross scrap sheet 42B together to form a cap sheet and thereby maintaining proper alignment and providing reliable placement of the bottom scrap sheet 42 A and the cross scrap sheet 42B. Referring back to FIG. 2, the conveyor assembly 30 has a plurality of trailing edge photo eye sensors 134A-C placed immediately downstream to the embosser assembly 120 to detect the trailing edge of the bottom scrap sheet 42 A, thereby indicating completion of the embossing of the cap sheet by sending a signal to the programmable logic controller 152. The cap sheet stacker 140 is selectively lowered and lifts the cap sheet to allow advancement of a second cap sheet below the cap sheet stacker 140 so that the lifted cap sheet can be lowered onto a second cap sheet to be simultaneously advanced. Laterally aligned end position photo eyes 142A-C detect the arrival of the cap sheet at another pinch roller assembly 1 12 located at the exit end 34 of the conveyor assembly 30 to signal the programmable logic controller AA for effectuating control of the pinch roller assembly 112. The cap sheet is then passed through the pinch roller assembly 112 for subsequent placement onto a selected site of a load former for the formation of a palletized load. Referring to FIG. 3, the bottom sheet drive belts 50 convey the bottom scrap sheet 42A such that the bottom scrap sheet 42 is oriented in the direction of the flow of the system. The pinch roll photo eyes 84A, 84B, and 84C detect the positioning of the bottom scrap sheet 42A on the bottom sheet dispenser 36 before it reaches the bottom sheet pinch rollers 86 at the end of the bottom sheet dispenser 36. The photo eyes 84 A, 84B, and 84C, in conjunction with the bottom sheet pinch rollers 86, detect the position of the bottom scrap sheet 42A while signaling the programmable logic controller 152 to deter the operation of the gear motor assembly 58 so that the alignment of the bottom scrap sheet 42 A can be corrected before the bottom sheet pinch rollers 86 facilitate advancement of the bottom scrap sheet 42 A onto the conveyor assembly 30. The cross sheet drive belts 50 of the cross sheet dispenser 38 (FIG. 5) convey the cross scrap sheet 42B such that the cross scrap sheet 42B is oriented to extend laterally to the conveyor 30, or perpendicular to the direction of the flow thereon. The cross sheet pinch roll photo eye 98, disposed at the symmetrical center before the pinch roller assembly 86 of the cross sheet dispenser 38, detects the position of the cross scrap sheet 42B on the cross sheet dispenser 38 before it reaches the cross sheet pinch rollers 86. The cross sheet pinch roll photo eye 98, in conjunction with the cross sheet pinch rollers 86, detects the position of the cross scrap sheet 42B while signaling the programmable logic controller 152 to deter the operation of the gear motor assembly 96 so that the alignment of the cross scrap sheet 42 can be corrected before the cross sheet pinch roller assembly 86 facilitates advancement of the cross scrap sheet 42 onto the conveyor assembly 30. As shown in FIG. 15, it will be appreciated that the cap sheet stacker 140 can be selectively raised or lowered via operation of the air cylinders 146 as controlled by the programmable logic controller 152. Further, it will be appreciated that the programmable logic for the programmable logic controller 152 need not be described as such programming is well .known to persons skilled in the art. As mentioned above, the sheet insertion apparatus 10 permits the use of various sized sheets, including scrap sheets, to form a cap sheet for palletizing loads of stacked blanks or any relatively flat product. FIGS. 12A through 12G depict several bottom sheet and cross sheet combinations which are possible with the controlled feeding of one or more sheets 42 A and 42B from the bottom sheet dispenser 36 and the cross sheet dispenser 38, respectively. These are: 1. FIG. 12A - bottom sheet only; 2. FIG. 12B - double bottom sheets; 3. FIG. 12C - bottom and cross sheet; 4. FIG. 12D - double bottom and cross sheets; 5. FIG. 12E - cross sheet only; 6. FIG. 12F - single bottom sheet with double cross sheets; and 7. FIG. 12G - double bottom sheets with double cross sheets. These are achieved by selectively loading sheets as required onto the belts 50 of the bottom sheet dispenser 36 and the cross sheet dispenser 38, as each has the capability of feeding one or two sheets onto the conveyor assembly 30. Of course, it will be recognized that multiple belts 50 can be added as required to dispense any number of bottom sheets and cross sheets as may be required. FIG. 13 depicts a finished load of cardboard blanks supported on a bottom sheet and a cross sheet. As described above, the sheet dispenser 10, via the embosser assembly 120, interconnects or stitches the bottom sheet and the cross sheet by the spur gear effect of the relatively sharp lobes 127 of the embossing rollers 126 penetrating the cross sheet and pushing the hole material thereof into the penetration of the bottom sheet. FIG. 14 illustrates a typical lobe penetration and the interlocking of the cross sheet and the bottom sheet thereby. FIGS. 12A through 12G also depict a typical stitching pattern that results from passing the sheets 42 through the embossing assembly 120. The lobes 127 of one embossing roller 126 is aligned with respect to the lobes 127 of each of the other embossing rollers 126 to create such a uniform stitching pattern as depicted in FIGS. 12A through 12G. It will be understood that different stitching patterns on the sheets 42 can be achieved by selectively orienting the lobes 127 of the embossing rollers 126 in a staggered pattern relative to the lobes 127 of other embossing rollers 126. It will also be appreciated that no interlocking of sheets will occur unless more than one layer of sheets are used to form the cap sheet. The present invention is particularly useful in pelletizing systems as the sheet insertion apparatus 10 provides for the use of variously sized material to form load caps for a wide variety of load foot prints. It will be clear that the present invention is well adapted to attain the ends and advantages mentioned as well as those inherent therein. While presently preferred embodiments have been described for purposes of disclosure, numerous changes may be made which will readily suggest themselves to those skilled in the art and which are encompassed in the spirit of the invention disclosed.

Claims: Claims 1. An apparatus for automatic foraiation of a cap sheet for use with a palletized load, comprising: a bottom sheet dispenser for dispensing bottom sheets of material; a conveyor for moving the bottom sheets to a selected position; and an embosser to embed stitches in the bottom sheets advancing from the bottom sheet dispenser, the stitches extending through the bottom sheets to maintain proper alignment and provide consistent placement of the bottom sheets. 2. The apparatus of claim 1 further comprising: a cross sheet dispenser for dispensing cross sheets of material onto the conveyor, the embosser embedding stitches in the cross sheet advancing from the cross sheet dispenser, the stitches extending through the cross sheets. 3. The apparatus of claim 2 wherein the second sheets from the cross sheet dispenser are dispensed at least partially overlapping a portion of the bottom sheets from the bottom sheet dispenser, and wherein the embosser simultaneously embeds stitches therein whereby at least one of the cross sheets and one of the bottom sheets are stitched together to form the cap sheet positioned on the conveyor, and wherein the conveyor moves the cap sheet to the selected position. 4. The apparatus of claim 3 further comprising: a controller operably coupled to the bottom sheet dispenser and to the cross sheet dispenser for selectively advancing the sheets to dispose the sheets in a selected relationship on the conveyor. 5. The apparatus of claim 4 wherein the controller comprises: detection means for detecting positioning of the sheets on the conveyor. 6. The apparatus of claim 5 wherein the bottom sheet dispenser has a dispensing end and the detector means comprises: a pinch roll photo eye sensor for detecting the position of a bottom sheet before the bottom sheet exits the bottom sheet dispenser at the dispensing end; and a plurality of pinch rolls located at the dispensing end of the bottom sheet dispenser. 7. The apparatus of claim 6 wherein the cross sheet dispenser has a dispensing end and the detector means comprises: a pinch roll photo eye sensor for detecting the position of a cross sheet before the cross sheet exits the cross sheet dispenser at the dispensing end; and a plurality of pinch rolls located at the dispensing end of the cross sheet dispenser. 8. The apparatus of claim 7 wherein the cross sheet dispenser dispenses a cross sheet so that the cross sheet is oriented in a direction perpendicular to the movement of the conveyor, the cross sheet being stitched by the embosser to a bottom sheet when the cross sheet and bottom sheet pass through the embosser to form the cap sheet. 9. The apparatus of claim 7 wherein the embosser comprises: an embossing roller for creating corresponding ridges in the sheets passing therethrough; and a support roller for backing up the embossing roller. 10. The apparatus of claim 9 wherein the embossing roller is a lobed roller and the support roller is a grooved roller. 11. The apparatus of claim 10 further comprising: a cap sheet stacker disposed above the conveyor, the cap sheet stacker having at least one vacuum suction cup coupled thereto to allow lifting of a sheet for placement onto a second sheet, thereby overlapping the sheets. 12. An apparatus for formation of a cap sheet for use with a palletizing load, comprising: a conveyor having an infeed end, a medial portion, and a sheet delivery end; a bottom sheet dispenser for dispensing bottom sheets of material onto the conveyor, the bottom sheet dispenser disposed proximate to the infeed end; a cross sheet dispenser for dispensing cross sheets of material onto the conveyor, the cross sheet dispenser being downstream from the bottom sheet dispenser to dispense cross sheets overlapping a portion of the bottom sheets; and an embosser assembly simultaneously embedding stitches in the bottom sheets and the cross sheets so that at least one of the bottom sheets and one of the cross sheets are stitched together to form a cap sheet, the conveyor moving the cap sheet to a selected position. 13. The apparatus of claim 12 wherein the embosser assembly further comprises a plurality of lobed embossing rollers and a plurality of grooved rollers in cooperation with the lobed embossing rollers, each of the lobed rollers having a pointed lobe whereby each of the grooved rollers matingly align and interact with a corresponding lobed roller to receive the lobe thereof and facilitating stitching of the bottom and cross sheets passing therebetween. 14. The apparatus of claim 13 further comprising a controller operably coupled to the bottom sheet dispenser and to the cross sheet dispenser for selectively advancing the bottom and cross sheets to dispose the bottom and cross sheets in a selected relationship on the conveyor, the bottom sheet dispenser and the cross sheet dispenser each having a dispensing end, the controller having detection means to detect positioning of the sheets on the conveyor, the detection means comprising. 15. The apparatus of claim 14 wherein the controller comprises:: a plurality of pinch roll photo eye sensors for detecting the position of one of the bottom sheets before such bottom sheet exits the bottom sheet dispenser at the dispensing end and for detecting the position of one of the cross sheets before such cross sheet exits the cross sheet dispenser at the dispensing end; and a plurality of pinch rolls located at each of the dispensing ends of the bottom sheet dispenser and the cross sheet dispenser for facilitating dispensing of the bottom and cross sheets onto the conveyor. 16. The apparatus of claim 15 wherein the cross sheet dispenser dispenses a cross sheet so that the cross sheet is oriented in a direction perpendicular to the movement of the conveyor, the bottom sheet dispenser dispenses a bottom sheet oriented in a direction of the movement of the conveyor so that the cross sheet is stitched by the embosser to the bottom sheet when the cross sheet and the bottom sheet pass through the embosser to form the cap sheet. 17. The apparatus of claim 16 further comprising: a cap sheet stacker disposed above the conveyor, the cap sheet stacker having at least one vacuum suction cup coupled thereto to allow lifting of a sheet for placement onto a second sheet, thereby overlapping the sheets. 18. A method for forming a cap sheet comprising the steps of: advancing a bottom sheet on a conveyor from a bottom sheet dispenser; advancing a cross sheet from a cross sheet dispenser onto the top of the bottom sheet such that the cross sheet and the bottom scrap sheet advance together to an embosser; stitching the bottom sheet and cross sheet together in the embosser such that the bottom sheet and the cross sheet are interlocked together to maintain proper alignment and provide consistent placement of the bottom sheet and cross sheet while forming a cap sheet; and conveying the cap sheet to a selected site. 19. The method of claim 18, wherein the step of advancing a cross sheet further comprises the steps of: advancing the conveyor a predetermined gap distance; conveying a second cross sheet on top of the bottom sheet on the conveyor such that the second cross sheet advances with the bottom sheet to the embosser; and stitching the bottom sheet and second cross sheet together in the embosser such that the bottom sheet and second scrap sheet are interlocked together to maintain proper alignment and provide consistent placement of the bottom sheet and the second cross sheet while forming a cap sheet. 20. The method of claim 19 f .urther comprising: lifting a sheet from the conveyor for placement onto a second sheet, thereby overlapping the sheets. AMENDED CLAIMS [recei ved by the Internationa l Bureau on 04 May 1999 ( 04.05.99 ) ; original claims 9 , 14 and 15 amended ; remaining cl a ims unchanged ( 2 pages ) ] 6 The apparatus of claim 5 wherein the bottom sheet dispenser has a dispensing end and the detector means comprises a pinch roll photo eye sensor for detecting the position of a bottom sheet before the bottom sheet exits the bottom sheet dispenser at the dispensing end, and a plurality of pinch rolls located at the dispensing end of the bottom sheet dispenser 7 The apparatus of claim 6 wherein the cross sheet dispenser has a dispensing end and the detector means comprises a pinch roll photo eye sensor for detecting the position of a cross sheet before the cross sheet exits the cross sheet dispenser at the dispensing end, and a plurality of pinch rolls located at the dispensing end of the cross sheet dispenser. 8 The apparatus of claim 7 wherein the cross sheet dispenser dispenses a cross sheet so that the cross sheet is oriented in a direction perpendicular to the movement of the conveyor, the cross sheet being stitched by the embosser to a bottom sheet when the cross sheet and bottom sheet pass through the embosser to form the cap sheet 9 The apparatus of claim 8 wherein the embosser comprises: an embossing roller for creating corresponding ridges in the sheets passing therethrough; and a support roller for backing up the embossing roller 10 The apparatus of claim 9 wherein the embossing roller is a lobed roller and the support roller is a grooved roller sheets in a selected relationship on the conveyor, the bottom sheet dispenser and the cross sheet dispenser each having a dispensing end, the controller having detection means to detect positioning of the sheets on the conveyor. 15 The apparatus of claim 14 wherein the controller comprises' a plurality of pinch roll photo eye sensors for detecting the position of one of the bottom sheets before such bottom sheet exits the bottom sheet dispenser at the dispensing end and for detecting the position of one of the cross sheets before such cross sheet exits the cross sheet dispenser at the dispensing end; and a plurality of pinch rolls located at each of the dispensing ends of the bottom sheet dispenser and the cross sheet dispenser for facilitating dispensing of the bottom and cross sheets onto the conveyor. 16. The apparatus of claim 15 wherein the cross sheet dispenser dispenses a cross sheet so that the cross sheet is oriented in a direction perpendicular to the movement of the conveyor, the bottom sheet dispenser dispenses a bottom sheet oriented in a direction of the movement of the conveyor so that the cross sheet is stitched by the embosser to the bottom sheet when the cross sheet and the bottom sheet pass through the embosser to form the cap sheet. 17. The apparatus of claim 16 further comprising: a cap sheet stacker disposed above the conveyor, the cap sheet stacker having at least one vacuum suction cup coupled thereto to allow lifting of a sheet for placement onto a second sheet, thereby overlapping the sheets.

Inventors: DRAKE JON P, GERST MICHAEL D, WEBB PATRICK J, DRAKE, JON, P., GERST, MICHAEL, D., WEBB, PATRICK, J.
Applicants: ASC MACHINE TOOLS INC, DRAKE JON P, GERST MICHAEL D, WEBB PATRICK J, ASC MACHINE TOOLS, INC., DRAKE, JON, P., GERST, MICHAEL, D., WEBB, PATRICK, J.
Application year: 1998
Main classification: B31B1
IPC codes: B65B41, B65H37, B65H39