Abstract:
A packaging machine for loading a plurality of articles into a carton which mechanism comprises carton erecting means for part erecting said carton to define a first article receiving cell, means for selecting a group of articles comprising at least two articles, means for separating said grouped articles from an adjacent like group of articles, means for loading said grouped articles into said first article receiving cell through an open end thereof in the packaging carton and a means for completing the construction of the carton. There also comprises a mechanism for forming a carton including a pair of article receiving cells comprising complementary die members, each said die member being mounted to a rotating wheel wherein each said complementing die member is adapted to interengage when a blank is positioned between the two members, such that said die members cause the blank to be folded to define said article receiving cells.

Description:
BACKGROUND OF THE INVENTION 
   This invention relates to a packaging machine which is especially suitable for processing multiple package cartons from blank form to completed filled multiple unit cartons and to a method of forming such cartons. The machine can be readily adjusted to accommodate a wide range of carton sizes without undue time being taken to adapt the machine for running one size of carton to running a different size of carton. 
   The majority of known packaging machines are dedicated machines which construct only size of one type of carton. Therefore, it is necessary to use a plurality of packaging machines to package different carton types, each machine taking up considerable floor space and being expensive to both purchase and operate. 
   In packaging machines which are required to construct cartons comprising internal compartments for holding a given number of articles, the construction of these cartons is often complex and often dictates the speed of the machine. What is required is a packaging machine which can construct compartments within a carton with a minimum number of folding operations. 
   A further problem arises when loading the articles into the compartments and in particular where those compartments are in a spaced arrangement. It is known to provide article metering mechanisms which continuously load a group of articles into cartons, for example, wrap-around cartons used in beverage multiple packs. However, where carton compartments are in a spaced relationship, it is necessary for some form of article grouping to be adapted. 
   SUMMARY OF THE INVENTION 
   It is an object of the present invention to provide a packaging machine which overcomes the technical and commercial disadvantages of known packaging machines. 
   In cartons where a display portion is provided, it is often desirable for display indicia to be shown through the display portion. The majority of known packaging machines are not able to orientate the display indicia on an article, for example, a label, so that it can be displayed. A limited number of packaging machines incorporate equipment to orientate the containers. However, this equipment is usually complex or extremely costly for example, use of survey motors or optic fibre and a printed colour spot on the label to identify (i) a suitable reference point and (ii) to align the reference point at the correct position. 
   Thus it is a further object of the present invention to provide a mechanism for incorporation into a packaging machine which is capable of orienting containers for example, batteries, using equipment which is relatively inexpensive and simple. 
   According to a first aspect of the invention there comprises a packaging machine for loading a plurality of articles into a carton which mechanism comprises carton erecting means for part erecting said carton to define a first article receiving cell, means for selecting a group of articles comprising at least two articles, means for separating said grouped articles from an adjacent like group of articles, means for loading said grouped articles into said first article receiving cell through an open end thereof in the packaged carton and a means for completing the construction of the carton characterised in that said carton erecting means comprises complementary die members, each said die member being mounted to a rotating wheel wherein each said complementary die member is adapted to inter engage when a carton blank is positioned between the two members, such that said die members cause the blank to be folded to define said receiving cells. Preferably, the carton erecting means may comprise a device which effects a change in configuration of the carton from an inoperative configuration in which said first article receiving cell is formed to receive said grouped articles. 
   According to an optional feature of this aspect of the invention one of the complementary members may comprise a protruding portion extending from a working face of the complementing member and wherein the other said complementing member comprises a recessed portion adapted to receive said protruding portion and wherein the blank is placed on said receiving member and wherein the protruding portion forces part of the blank into said receiving portion. 
   According to another optional feature of this aspect of the invention one of the complementary members may comprise a protruding portion extending from a working face of the complementing member and wherein the other said complementing member comprises a recessed portion adapted to receive said protruding portion and wherein the blank is placed on said receiving member and wherein the protruding portion forces part of the blank into said receiving portion. 
   According to another feature of this aspect of the invention the selecting means may comprise a plurality of channels mounted on an endless chain which channels are grouped to correspond to the number of articles to be placed into the first article receiving cell and wherein the channels are adapted to substantially align each article with the first article receiving cell. 
   According to another feature of this aspect of the invention, the carton may comprise a second article receiving cell formed by the carton erecting means in a spaced relationship to the first article receiving cell wherein the grouped channels comprise at least two channels in substantially parallel relationship to one another wherein said at least two channels are adapted to diverge into a plurality of sub-groups wherein each sub-group is spaced to align an article held in each sub-group with one of the article receiving cells. 
   optionally, the packaging machine of this aspect of the invention may further comprise a conveyor including means to convey the articles and means to regulate the flow of articles to enable the articles to be aligned with each carton. 
   A second aspect of the invention provides a method of loading a plurality of articles into a carton whilst the articles and carton are moved in a synchronised manner and in a continuous forward direction comprising the following steps: 
   transferring carton blank from a stowed position and erecting the blank to form the carton; 
   selecting a group of articles to be loaded into the carton; 
   synchronously associating an article receiving cell formed from the blank with a given number of said grouped articles by sideways movement of the articles; and 
   transferring the carton and loading said grouped articles into a carton through an open end thereof. The blank is erected by erecting means comprising complementary die members, each die member being mounted to a rotating wheel wherein each complementary die member is adapted to inter engage when a blank is positioned between the two members, such that the die members cause the blank to be folded to define the article receiving cells. 
   A third aspect of the invention provides a mechanism for forming a carton including a pair of article receiving cells comprising complementary die members, each die member being mounted to a rotating wheel wherein each complementary die member is adapted to inter engage when a blank is positioned between the two members, such that the die members cause the blank to be folded to define the article receiving cells. 
   According to an optional feature of the third aspect of the invention, one of the complementary members may comprise a protruding portion extending from a working face of the complementary member and wherein the other complementary member comprises a recessed portion adapted to receive the protruding portion and wherein the blank is placed on the receiving member and wherein the protruding portion forces part of the blank into the receiving portion. 
   A fourth aspect of the invention provides a mechanism for grouping a plurality of articles which mechanism comprising an endless series of channels along which articles may be transferred into a plurality of article receiving cells of a carton wherein the channels are organised into groupings whereby each grouping corresponds to a given number of articles to be loaded in the carton. 
   According to an optional feature of the fourth aspect of the invention the channels are adapted to be substantially parallel to one another and then diverge into sub-groupings wherein each sub-group is spaced to align an article held in each sub-group with one of the article receiving cells corresponding to each one of the cells of each carton and wherein the sub-groupings are each substantially parallel to one to provide in line parallel access to the cells. 
   A fifth aspect of the invention provides a mechanism for causing a label affixed to an article to be oriented to a predetermined display position wherein the article includes a portion protruding outwardly of the article in a fixed position relative the label, wherein the mechanism comprises support means adapted to support an article, orientation means adapted to cause the article to rotate in the support means until the protruding position is restrained by abutment means formed in the support means. Preferably, one edge of the label affixed to the article overlays an opposed edge of the label to define the protruding portion. 
   According to an optional feature of this aspect of the invention, the support means may comprise a channel including a support surface to retain part of the article within the channel. Preferably, the support surface may substantially correspond to the exterior surface of the retained part of the article. 
   According to another optional feature of the fifth aspect of the invention the orientation means may comprise an elongate member connected to resilient means, wherein the elongate member is adapted to abut a portion of the article as the support means is moved in a substantially parallel plane to the elongate member such that a tangential force is applied to the abutting portion of the article to cause the article to rotate. Optionally, the resilient means may be adapted to reduce the tangential force when the protruding portion is restrained by the abutment means. 
   According to a further optional feature of the fifth aspect of this invention, the abutment means may be formed from an upper edge of the channel. 
   A sixth aspect of this invention provides a method of orienting to a predetermined display position wherein the article includes an outwardly protruding portion in a fixed position relative the label a label affixed to an article which method comprising the steps of supporting the article in support means during forward movement, rotating the article within the support means until the protruding portion abuts a portion of the support means and retaining the article in its desired orientation for loading into a carton. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which: 
       FIG. 1  is a perspective view of a selection of “blister pack” type cartons packaged by a machine according to one or more aspects of the invention. 
       FIG. 2  is a plan view of a unitary blank used to construct one type of carton capable of being used with a machine according to the invention. 
       FIG. 3  is a perspective view of one type of carton formed from the blank shown in  FIG. 2 . 
       FIG. 4  is a perspective view of a machine according to one or more aspects of the invention. 
       FIGS. 5   a  and  5   b  are perspective views of the carton supply in-feed and set-up stations of the machine shown in  FIG. 4 . 
       FIG. 6  is a perspective view of the carton conveyor and loading station of the machine-shown in  FIG. 4 . 
       FIG. 7  illustrates one type of article to be packaged by the machine according to the invention. 
       FIGS. 8   a , and  8   b  illustrate a mechanism for orientating the labels affixed to an article according to another aspect of the invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The machine according to the present invention is capable of loading cartons comprising compartments for retaining a given number of articles within each compartment. A selection of cartons(CA 1  to CA 6 ) suitable for being packaged by such a machine is illustrated in  FIG. 1 . 
     FIG. 2  shows an example of a carton which can be constructed and loaded by a packaging machine of the present invention. Thus, there comprises a unitary blank  10  formed from paperboard or other suitable material, which blank  10  comprises a series of panels hinged one to the next. Thus support panel  12  in hingably connected to top panel  14  along fold line  30 . Top panel  14  is connected by way of fold line  32  to side panel  16 . Side panel  16  is hingably connected along fold line  34  to bottom panel  18 . Base panel  18  is hingably connected to second support panel  20  by means of fold line  36 . In a set up condition, support panels  12 ,  20  are connected together in a face to face relationship by glue or other suitable means. 
   End panel  22  is hingably connected to side panel  16  along fold line  38  and strengthening panel  24  is hingably connected by means of fold line  40  to the opposing side of end panel  22 . Likewise, end panel  26  is hingably connected to side panel  16  along fold line  42  and strengthening panel  28  is hingably connected to the opposing side of end panel  26  along fold line  44 . 
   In a set up condition, top panel  14 , side panel  16 , bottom panel  18  and a portion of support panel  20  co-operate to form a hollow display box. End panels  22 ,  26  provide closures for the box, with strengthening panels  24 ,  28  being secured, such as by gluing, to support panel  20  to maintain the box in set up condition. Side panel  16  provides a display face for the package, while support panel  20  provides a back panel. 
   The carton incorporates two securing cells or display windows C 1 , C 2  constructed from partition sections  96 ,  98  as illustrated in  FIG. 3 . Turning again to  FIG. 2 , partition section  96  is struck from side panel  16  and end panel  22  along opposing cut lines  50 ,  52 . Partition section  96  is hinged to side strengthening panel  24  along fold line  40 . When the carton is in a set up condition, this partition section will define an individual cell. Likewise partition section  98  is struck from side panel  16  and end panel  22  along opposing cut lines  50 ,  52 . Partition section  96  is hinged to side strengthening panel  24  along fold line  40 . When the carton is in a set up condition, this partition section will define an individual cell. 
   It is envisaged that the carton can vary depending upon the shape and/or quantity of articles to be packaged and accordingly, a machine in accordance with the present invention is adjustable in numerous respects so that it can process a wide variety of such cartons and is not limited to the specific example outlined above. 
   Referring now to  FIG. 4  of the drawings, there is shown a machine for processing cartons  52  of the type outlined above. The upstream end of the machine includes a hopper  54  in which a multiplicity of cartons  52  in flat collapsed condition are held ready for processing. As shown in  FIGS. 4 and 5 , the cartons are removed from the hopper  54  sequentially by a rotary vacuum feeder  56 . The vacuum feeder  56  comprises four pairs of suction cups  58  each being connected to a drive shaft  60  by a drive rod  62 . Driving means  64  for example a servo motor, is used to rotate the drive shaft  60 . The drive shaft  60  can be connected to a cam track by a cam rod not shown to provide a uniform path with suction cups when the drive shaft  60  is rotated. 
   The hopper  54  is, in this embodiment, a ‘gravity feed’ type whereby the carton blanks  52  are held on the hopper at an incline to provide a positive feed. Thus as shown in  FIG. 5 , a carton in flat collapsed condition is removed from the hopper  54  and is rotated by the vacuum feeder  56  to the in-feed end of the machine  54 . The blank is placed onto a pair of endless chains  66 ,  68 , for example, side lug chains, and is held in position by suitable support means, for example leading and trailing lugs  70 ,  72  mounted upon the endless chains  66 ,  68  respectively. The lug sets  70 ,  72  maintain the position of the carton and move the carton downstream to the set-up station shown generally at  74 . 
   The set-up station  74  is shown in  FIG. 5 , and it includes a pair of rotating wheel units  76 ,  78  which, in this embodiment, are positioned above and below the carton. Of course, the position of the units is not limited to their position shown in the drawings. The rotating wheels  76 ,  78  can be powered by known driving means for example servo motors. In this embodiment, each rotating wheel unit  76 ,  78  comprises a pair of die members  80 ,  82 ,  84 ,  86  mounted to each rotating wheel by a shaft  88 ,  90 . Each wheel unit  76 ,  78  in opposed positions includes cam track and cam as described below. In other embodiments, the rotating wheels  76 ,  78  can comprise more than two die members, if manufacturing requirements or the packaging speed dictate that such a modification be preferable. Turning to the construction of the die members  80 ,  82  of the upper wheel  76 , it is envisaged in this embodiment that both die members  80 ,  82  are identical in construction, so only one of the members  80  is described in any greater detail. As illustrated in  FIGS. 5   a  and  5   b , the upper rotating wheel  76  comprises a (male) die member formed from a substantially rectangular block  92  mounted to the rotating wheel  76  by a shaft  88 . In use, the wheel rotates in direction “B” A protruding portion extends from the lower surface  100  of the block. In this embodiment, the protruding portion is shaped to correspond to the width “W” between adjacent fold lines  35 ,  37 , shown in  FIG. 3 , and the remaining portion of the lower surface  100  is shaped to correspond to partition sections  96 ,  98  defining the article receiving cells C 1 , C 2 . 
   Likewise, the lower rotating wheel  78  comprises the corresponding (female) die member  84 ,  86  formed from a substantially rectangular block  102  mounted to the rotating wheel  78  by a shaft  90 . In use, the wheel rotates in direction “C”. The upper surface  104  of the block comprises a recessed portion  106  which is shaped to receive the corresponding protruding portion  94  from the lower surface  100  of block  92 . As the carton blank  52  is moved forward by the endless chains  60 ,  68 , the lower surface of the carton blank  52  comes into contact with the (female) die member  84  or  86 . 
   Preferably, the block  92  mounted to the upper rotating wheel  76  is rotated in unison with the lower block  102 . Thus, the upper block  92  can come into contact with the upper surface of the carton blank  52 . As the upper and lower blocks  92 ,  102  continue to move in directions B and C respectively, the cam track and cam arrangement within the rotating wheels  76 ,  72  cause the blocks to interengage whereby the protruding portion  94  is received by the corresponding recessed portion  106 . In this embodiment, the side panel  16  is thereby pushed in a downward direction and folded about fold lines  35 ,  37  to erect a pair of display windows or cells C 1 , C 2 , as shown in  FIGS. 5   a  and  5   b . The upper and lower blocks  92 ,  102  are then separated to release the carton  52  as it moves forward to the loading station  150  by the leading and trailing lugs  70 ,  72  on the endless chains  66 ,  68 . It is envisaged that the setting up station  74  and the process of “punching” the carton into a part erected form is a continuous process so that the carton is moved in a continuous forward direction as the carton erecting operation is performed. 
   If an alternative type of blister pack is required to be packaged, then the blocks  92 ,  102  can be connected to the rotating wheel units by suitable securing means (not shown), for example quick release mechanism, so that the blocks can be interchanged with a second pair of differently configured blocks which can be used to part erect a second carton type. 
   After the cartons have been part erected to define article receiving cells, they are successively transferred to the loading station  150  shown in  FIG. 4  by which the cartons move downstream by the pair of side lug chain sets  66 ,  68 . 
   At the loading station  150 , articles (A), for example batteries, are fed into the machine  50  by an end feed conveyor  152  and the line pressure of the batteries is controlled by an in feed star wheel  154 , as is well known. Thereafter, the articles may be transferred from the end feed conveyor  152  to an article grouping conveyor  156  shown in  FIG. 6 . The article grouping conveyor  156  separates the articles into groups of the correct number per blank by means of a series of channels  158  mounted to an endless chain  160 , which articles (A) can be transferred into a plurality of articles receiving cells, C 1 , C 2  (for example, two) of the carton. 
   As shown in  FIG. 6 , the channels  158  are organised into groupings, for example, four, whereby each grouping  162  corresponds to a given number of articles to be loaded in the carton. Suitable guide means (not shown), for example, guide rail and static guide, are used to push the articles in to the respective cells, and the grouping conveyor  156  is used to control the flow of articles (A) so that they can be introduced to the carton  52  at the same rate as the carton blank flow. 
   In the class of embodiments which include cartons with more than one article receiving cell, then the channels  158  are adapted to diverge into sub-groupings  164  whereby each sub-group  164  is spaced to align an article or articles (A) held in each sub-group  164  with one of the article receiving cells C 1 , C 2 . As shown in  FIG. 6 , each sub-grouping is shaped to provide channels  158  which are substantially parallel to corresponding article receiving cells C 1 , C 2  in order to provide in-line parallel access to the aforesaid cells. 
   Optionally, the machine may include a mechanism  200  shown in  FIG. 8  for causing a label  202  affixed to an article (A) to be oriented to a pre-determined display position. Preferably, the articles to be packaged include a portion protruding  203  outwardly of the article in a fixed position relative said label. As shown in  FIG. 7 , the protruding portion  204  is formed by the side edges  206 ,  208  of the label  202  being placed in an overlapping relationship. As the articles are moved forward, they are inserted in to support means  210  adapted to support the articles (A). As shown in  FIG. 8   a , the support means  210  comprises a group of channels (or holding combs)  212  adapted to receive part of an article. In this embodiment, each channel comprises a support surface  214  which substantially corresponds to the shape and configuration of the outer surface of the article (A). Of course, the different profiles of channel can be used, for example, a square d section, without departing from beyond the scope of the invention. Adjacent each channel  212  there comprises abutment means  216  adapted to restrain the protruding portion  204  of the article. In this embodiment, a surface  218  connecting adjacent channels  212  is used as the abutment (or pre-set stop) means  216 . 
   Referring again to  FIG. 8   a , each channel  204  is loaded with an article and the articles are successively moved forward to the orientation means  220  which is adapted to cause the articles to rotate in the support means  210 . The orientation means  220 , illustrated in greater detail in  FIG. 8   b , comprises an elongate member  222  held in a fixed position relative to the channels  212 . The elongate member  222  (or static member) can comprise a strip  224  including a working surface  226 . Alternatively, the elongate member  222  can comprise a flexible belt (not shown) held in a fixed position, or driven in a direction substantially opposed to direction “Z” shown in  FIG. 8   b . The working surface  226  preferably includes a layer of friction inducing material  228 , for example, rubber or other suitable plastic materials. The strip is connected to a support frame (not shown) by resilient means  230 , for example, a spring mechanism. Preferably, the length of the strip  224  should be equal to or greater than the circumference of the article (A) being rotated to ensure that each article can be rotated by up to 360 degrees. 
   As shown in  FIG. 8   b , the articles and channels  204  are moved in direction “Z” and are brought into contact with the orientation means  220 . Therefore, the strip  224  comes into contact with the upper portion of the article and as it is fixed relative the articles and channels  204  a tangential force is applied by the orientation means  220  to the articles which causes them to rotate. The channels  204  continue to move forward and the articles (A) continue to rotate until the protruding portion  203  comes into abutment with the abutment means  216 . Thus, the article is orientated to the correct position and can then be loaded into the cartons. 
   Once the article (A) has been oriented to its correct position, the increased resistance of the article when it ceases to rotate applies an upward force to the strip  224 . The resilient means  230  is used to reduce the tangential forces applied to the article (A) by the orientation means  220 , whereby the strip  224  is capable of being moved by small amounts in a vertical plane “Y” in order to prevent or at least minimise the prospect of a carton label  202  being torn or damaged. 
   It is envisaged that the article orienting mechanism can be incorporated into a machine described above, for example, at the upstream end of the grouping conveyor. It is further envisaged that this mechanism can be used in various types of packaging machines. Alternatively, the article orienting mechanism of the present invention can be sold as an individual module to be fitted to new equipment or to existing equipment on a retro fit basis. 
   At the loading station  150  shown in  FIG. 6 , the groups of articles or sub-groupings are introduced to the carton from one side as the carton and article group are moved forward in unison. The lateral movement of the carton in the loading station is controlled by a pair of guides  159 ,  161  positioned adjacent the end panels  22 ,  26  of each carton. It is envisaged that in other embodiments a pressure belt could replace fixed guides or, where appropriate, those particularly mounted endless chain and lug sets could be used. 
   Once the cartons have been loaded with articles, they are transferred by means of a conveyor  163  and/or a pressure belt to a further set of endless chains  165  with side lugs which are used to transfer the carton to the outfeed end of the machine shown, in  FIG. 4 . During this stage, the second support panel  20  is folded upwardly, and around the articles, by means of a fixed guide (not shown). Further, the end panels  22 ,  26  are folded about fold lines  38 ,  42  to enclose the article receiving cells C 1 , C 2  by a folding wheel  167  and glue flaps  24 ,  28  are connected to the cells C 1 , C 2  by glue or other means known in the art. Support panel  12  is then folded and secured to panel  20  by suitable securing means, for example glue or other means known in the art. Thereafter, pressure belts  169  can be applied to the carton to secure the panels in place and to complete the forming process. 
   Further modifications may be made without departing from the scope of the present invention. In particular, alternate sensors and alternate means of positioning each of the moveable articles may be utilised without departing from the scope of the invention as claimed in the accompanying claim. In addition, while the preferred embodiment described herein is for loading batteries into cartons, it will be recognised that the invention is not limited to cartons for batteries. The invention may be used with the machines for packaging cans, paperboard bricks, bottles and other containers into cartons. Further, the present invention is able to process cartons comprising numerous configurations of groups of articles covering a range of carton sizes and shapes, for example two, four, six or eight articles, without undue time being spent in adjusting the mechanism.