Abstract:
A taped bag feeder having a housing with a bag guide positioned thereon, a drive mechanism, a first reel and second reel for supplying an assembly of imbricated taped bags to a packaging operation. The assembly of imbricated taped bags having a pair of tape strands connected to the first and second reels which are rotated by the drive mechanism thereby advancing the assembly. The first and second reels being disposed on a face of the bag feeder parallel to and spaced from a longitudinal axis defined by an upstream end and downstream end of the bag guide.

Description:
TECHNICAL FIELD 
   The present disclosure relates to the field of packaging machinery. Specifically, the present disclosure is for a feeding mechanism used in supplying imbricated, or shingled, taped bags to a packaging machine. 
   BACKGROUND OF THE INVENTION 
   Taped bags and machinery using such bags are generally well known in the art. For example, U.S. Pat. No. 3,587,843 discloses a chain of imbricated bags connected and supported by two strands of tape; U.S. Pat. No. 3,698,547 discloses a packaging apparatus having imbricated bags connected by two strands of tape which are attached to a rotatable spool; U.S. Pat. No. 4,032,038 discloses a taped bag dispenser having a wind-up surface; U.S. Pat. No. 4,796,412 discloses a taped bag feeder having the take-up reels housed within a cassette; and British Patent Application GB 2 064 477 A discloses taped bag dispenser with a drive means for imparting rotational motion to take-up reels. 
   Typically taped bags are made from various thermoplastic materials. Common thermoplastic materials known in the art include polyethylenes, polyesters, ethylene vinyl alcohols (EVOH), and other polymers known in the art which may be configured alone or in combination depending on the desired properties of the packaging material. Taped bags are supplied in a folded or rolled arrangement with the leading end, typically the open end of the bag, configured in an imbricated, or shingled, arrangement with the leading edge of a subsequent bag offset behind the leading edge of a previous bag. Typically, a pair of tapes is provided to advance the bags into machinery that inserts product into the bag. Taped bag packaging equipment is commonly used in food packaging applications, particularly meat packing. 
   Taped bag feeders are used throughout meat packaging plants to aid in loading products efficiently into an opened bag. These taped bag feeders utilize bags that are shingled on evenly spaced tape. By using the tape as an advancing mechanism, the taped bag feeder, by use of a drive unit, can ensure an opened bag is always ready for an operator or machine to place product into. The drive mechanism on the taped bag feeder is coupled to take-up reels to draw the bags forward. The tapes are removably attached to the bags by adhesive or other means. When product has been inserted into a bag, the bag is peeled away from the tapes and moved to the next stage in the packaging operation. 
   Most packing plants are very cramped and do not leave very much space for workers and thoroughfares. One major problem with current taped bag feeders in the industry is that the take-up reels are aligned concentrically with the output shafts of the drive. This means that there is a take-up reel on each side of the taped bag feeder. Since many of these taped bag feeders are part of full production lines, it is hard to access the non-operator side reel. This costs valuable production time as workers need to walk around to the nearest opening or stoop below low conveyors to access the non-operator side reel. In a typical packaging operation, taped bags must be reloaded into the machine at periodic intervals, commonly every 30-45 minutes at a minimum. Therefore, an operator must access the take-up reel on the non-operator side of the machine to empty the accumulated tape and to feed the new tape for the next batch of bags. Production time is consumed in accessing the rear reel. 
   Another reason for the present invention is that some automated pieces of equipment are beginning to use taped bag feeders integrated into the machines. Due to the design of these complete packaging systems, access to the back-side is limited or fully guarded. Mounting the taped bag feeder on carriage rails is one option, but this adds much cost to the overall equipment. Additionally, the use of carriage rails is not a desirable option because of housekeeping and sanitation concerns, especially in food packaging applications. Carriage rails provide surfaces for the accumulation of dust, dirt, food scraps, or other contaminants, and require labor intensive cleaning. This adds much expense and requires workers to remove the whole tape bag feeder from the machine every time access is required at the back-side reel. Therefore, it is desirable for an easier way to allow workers to access the take-up reels without hindering production up-time. 
   Additionally, the current method of changing and or splicing tape on the non-operator side take-up reel of standard taped bag feeders was not very effective. Operators often have to crawl under very low conveyors or walk to a catwalk in order to reach the opposing tape reel located on the opposite side of the line. This can cause back strain as well as cross contaminate production areas as an operator may come in contact with the floor or peripheral area. Operator safety, coupled with additional machine down-time is why the present invention is desired. 
   SUMMARY 
   In view of the foregoing discussion, it is desirable for a taped bag feeder having both take-up reels accessible to an operator. This is accomplished by positioning both take-up reels on one side of the machine that is along side the bag flow path rather than in-line with the flow path. In other words, the take up reels may be positioned on the side of the feeder rather than on the downstream end. 
   One embodiment of the present disclosure incorporates a timed drive pulley arrangement attached to parallel shafts. By keeping the pulley ratio the same between the two shafts, a 1:1 windup ratio could be maintained between the two take-up reels. By bringing the second parallel shaft back through the body of the taped bag feeder, both reels could be placed on the operator side of the machine. 
   To further simplify the design, a second embodiment of the present disclosure incorporates a direct drive gear system internal to the taped bag feeder. This allows for a smaller package, and a more dependable drive arrangement. An intermediate parallel shaft is incorporated with a free-turning spur gear to ensure the secondary take-up reels rotate in the same direction and for ease of threading by the operator. 
   The major benefit of the present disclosure is that both reels of the taped bag feeder are located on one side of the unit, the operator side. Therefore, when a worker needs to obtain access to the tape reels, they do not have to take extra time out of production to go around to the opposite side of the machine. This is typically done when the carrier tape breaks, box of bags needs to be changed, or simply the tape needs to be emptied from the tape reels. 
   The taped bag feeder of this disclosure also allows the machine to be placed against a wall or other equipment that does not allow rear access for tape reel removal. Formerly, this was not possible or the machine had to be moved to gain access. 
   The device of the present disclosure can be used to advance shingled tape bags for a worker in a meat packing plant. The device may include a bag guide whereby bags are brought over the guide and the tape threaded over the properly spaced tape guide slot. The spaced tape guide may include various slots to run the tape through depending on the tape spacing when attached to the bags. The tape is then fed through the round tape guides and presented to the take-up reels. A simple knot is tied in the end of each tape strand and slid into the slot in the outer reel, knot facing out. The tape that is threaded through the round tape guide closest to the side-plate gets attached to the reel closest to the side-plate. The second tape running through the other round tape guide gets attached to the second reel. As bags are pulled off the tape over the bag guide, a sensor located atop the guide prompts the drive mechanism to advance the tape forward by means of the take-up reels. Thus, the bag-train advances forward, pulling up the next bag to be inflated and then filled with product. 
   A compressed gas stream is used to separate the bag mouth and inflate the bag. In one embodiment, an air amplifier or nozzle located upstream of the bag opening is used to open the bag and maintain it in its opened state. This air supply can run continuously for fast paced operations, or be activated via sensor means to save utility costs on slower equipment. An operator or machine is then able to push product into the opened bag and remove the bag from the tape. The product is then free to move to downstream packaging equipment. In addition to air, certain other compressed gasses may be used to open the bags, such as nitrogen, carbon dioxide, or other gasses depending on the desired atmosphere within the final package. 
   The device of the present disclosure was specifically designed for use in taped bag feed operations, but might be adapted to other uses. This concept could be applied to rewinding of scrap or trim from a manufacturing process. 
   One aspect of the present disclosure is a taped bag feeder having a housing with an upstream end, a downstream end and a longitudinal axis therebetween which defines a direction of flow or a drive path for a bag, a drive mechanism operatively connected to a first shaft having a first end and an opposing second end and a second shaft having a first end and an opposing second end, a first reel disposed on a first end of the first shaft and a second reel disposed on a first end of the second shaft. The drive mechanism is adapted to impart rotation to the first and second reels through the first and second shafts such that the first and second reels receive and wind the tape strands upon the reels, and advance the assembly of imbricated bags along the drive path from the upstream end to the downstream end. The first and second reels are both disposed on a face of the housing and oriented in a plane spaced from and parallel to the longitudinal axis of the housing. 
   Alternatively, the present invention is directed to a taped bag feeder having a drive mechanism further comprising a ratchet shaft having a first end and an opposing second end, and positioned between and operationally connected to the first and second shafts such that the first shaft is operationally connected to the second shaft by means of the ratchet shaft. 
   The present invention is a taped bag feeder comprising drive mechanism further including a differential unit positioned between the second end of the first shaft and a first end of a third shaft, and configured to maintain a substantially equal torque loading on the first and second shafts. The first and third shafts are operationally connected to the differential unit and along a common longitudinal axis therethrough. 
   The present disclosure is a taped bag feeder having a drive mechanism further comprising a pneumatic cylinder pivotally connected adjacent to a first end of a ratchet shaft such that the pneumatic cylinder imparts rotational motion to the ratchet shaft. 
   The present disclosure is directed to a taped bag feeder having a drive mechanism further comprising a means for transferring motion from a third shaft to a second shaft. Preferably, the means for transferring motion from a third shaft to a second shaft includes a first gear positioned on an opposing second end of a third shaft and a second gear positioned on an opposing second end of a second shaft. 
   The present disclosure is directed to a taped bag feeder having a drive mechanism which may further comprise a means for maintaining rotation of a first shaft, a second shaft and a third shaft, all in one direction. Preferably, the means for maintaining rotation of a first shaft, a second shaft and a third shaft, all in one direction, includes a third gear positioned on an opposing second end of a ratchet shaft. 
   Additional features will become apparent to those skilled in the art upon consideration of the following detailed description of drawings, illustrative of at least one embodiment of the disclosure. 

   
     BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
       FIG. 1  is a perspective view of a taped bag feeder of the present disclosure showing the operator side; 
       FIG. 2  is a perspective view of the taped bag feeder of  FIG. 1  disclosure showing the non-operator side; 
       FIG. 3  is an exploded view of the drive mechanism for the taped bag feeder of  FIG. 1  taken from the operator side; 
       FIG. 4  is an exploded view of the drive mechanism for the taped bag feeder of  FIG. 1  taken from the non-operator side; and 
       FIG. 5  is an exploded view of the differential assembly of the taped bag feeder of  FIG. 1 . 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   While the present disclosure will be described fully hereinafter with reference to the accompanying drawings in which a particular embodiment is shown, it is understood at the outset that persons skilled in the art may modify the disclosure herein described while still achieving the desired result of this disclosure. Accordingly, the description which follows is to be understood as a broad informative disclosure directed to persons skilled in the appropriate arts and not as limitations of the present disclosure. 
   Referring to  FIGS. 1 and 2 , an embodiment of the taped bag feeder of the present disclosure has a housing with an operator-side panel  52 , a non-operator side panel  54 , an upstream panel  56  and a downstream panel  58 . Taped bags  1  may be loaded into the feeder from an external source, such as a box  2  or a reel (not shown). The bag train is brought over the top of the bag guide  3  with the tape strands  4 ,  5  facing down so the bags can be opened from the top with an air amplifier or nozzle  6 . Tape guide  7  has a number of openings, channels, slots, grooves, or the like, positioned side-by-side to receive tape strands  4 ,  5  spaced at typical dimensions, as is generally known in the packaging industry. The two tape strands  4 ,  5  are then placed in the appropriate spacing of the tape guide  7  to keep the two tapes parallel. 
   Tape guides  8   a ,  8   b  are positioned to correspond to the take-up reels  34   a ,  34   b , respectively. Take-up reels  34   a  and  34   b  are horizontally offset from each other to prevent interference between the tape strands, therefore tape guides  8   a  and  8   b  are offset to align with their corresponding take-up reel. From the tape guide  7 , the tape gets threaded through the aperture in the round tape guides  8   a ,  8   b  located inline with two take-up reels  34   a ,  34   b.    
   A knot is tied in the end of each tape strand  4 ,  5  and slid into the slot  11  on reel  10 , knot facing out. The tape  4  that is threaded through the round tape guide  8   a  gets attached to the corresponding inline reel  34   a . Tape  5  runs through the second round tape guide  8   b  and gets attached to the second reel  34   b.    
   To start, the bags  1  should be located behind the switch actuator  13  (see  FIG. 3 ), which protrudes from the bag guide  3 . If bags  1  are located over the top of the switch actuator  13  (see  FIG. 3 ), several bags should be removed from the two strands of tape  4 ,  5  to ensure the bags  1  will be in the correct position during the first cycle. 
   The tape bag feeder advances bags  1  forward as an operator or machine moves product  14  into the opened bag  15  on the bag guide  3 . Bags  1  are opened by use of a compressed gas stream. In the embodiment shown, a pneumatically operated air amplifier or nozzle  6  is focused towards the bag opening. The bag  15  to be filled is popped open from the air turbulence as the lower portion of the bag is held by the two pieces of tape  4 ,  5 . As bag  15  is removed, the switch actuator  13 , which was held down by the just removed bag, tips upward, prompting advance switch  18  to activate. 
   Referring now to  FIGS. 3 and 4 , the switch actuator  13  being in the upper position causes pneumatic cylinder  19  to advance by way of an electronic solenoid valve or air operated logic switch, both of which are generally known in the art. A dual acting air cylinder  19  is given brief bursts of air, alternating between ports  20  and  21 , rotating the pivot arm  22  forward and back. Pivot arm  22  is connected to the ratchet shaft  23  via a one-way needle clutch bearing  24 . Bearing  24  grips the ratchet shaft  23  firmly in the push stroke and rolls freely in the opposite direction. Therefore, as the cylinder  19  actuates back and forth, the ratchet shaft  23  rotates in one direction advancing the downstream components. Ratchet shaft  23  is supported by two bearings  42 , one on each end. 
   Firmly affixed to the ratchet shaft  23  is a spur gear  25 . Gear  25  mates to another spur gear  26  attached to the outer housing of differential unit  28 . Differential  28  consists of three shafts each with bevel gears incorporated into them, as is shown in  FIG. 5 . The two output shafts, primary  29  and secondary  30 , have a bevel gear  31  affixed to their ends internal to the differential housing. Gears  31  mesh with bevel gears  33  on differential cross shaft  32 , held in place by the differential housing. Shaft  32  is perpendicular to output shafts  29  and  30 , and runs through the center of the differential  28 . The two bevel gears  33  are free to rotate on the cross shaft  32 . Therefore as the main spur gear  26  turns the outer housing of differential  28 , both output shafts  29  and  30  rotate with the differential  28  as long as the output shafts  29  and  30  have similar torque loads. This is because equal loads are distributed through the gears  31  and  33  to the differential cross shaft  32 , which turns with the differential  28 . If one of the output shafts, for example shaft  29 , is held in place as the differential  28  housing rotates, the other corresponding output shaft  30  turns twice as fast to allow the housing to continue moving. This happens as the internal bevel gears  33  now engage the non rotating output shaft  29 . This creates the extra rotational speed as 50% of the movement comes from the housing differential  28  movement and the other 50% comes from the rotational movement of the internal bevel gear  33  relative to the non-rotating shaft  29 . By use of such a differential  28 , tensions between the two spaced tapes  4  and  5  can be kept the same. This equalization of tensions ensures the shingled bags  1  track properly through the taped bag feeder and allows variations in tape length to be accounted for. 
   Referring again to  FIGS. 3 and 4 , each of the output differential shafts  29  and  30  is supported by outboard one-way needle clutch bearings  24 . Each of these bearings  24  ensures the shafts  29  and  30  do not rotate in the opposite direction, which could cause the tape  4 ,  5  on the reels  34   a ,  34   b  to become loose. The primary differential shaft  29  is connected to a backing plate  9  having a hub (not shown). A removable outer plate  10  attaches on the end of the primary output differential shaft  29  via a hand knob  38  or similar mechanism. Backing plate  9  and outer plate  10  cooperate to form a take up reel  34 . The hub of backing plate  9  provides a gap with the outer plate  10  allowing tape  4  to be accumulated for disposal. The outer plate  10  has a slot  11  to accept a tape  4 ,  5  with a knot in the end. The knot gets placed on the outer side of the outer plate  10 , so as to wind-up a length of tape  4 ,  5  as it is used up from the supply of bags  1 . This allows for removal of tape  4 ,  5  after it has accumulated to the outer diameters of the reels  34   a ,  34   b.    
   The secondary output differential shaft  30  has another spur gear  39  affixed to it. Gear  39  meshes with an intermediate spur gear  40  that rolls freely on the opposite end of the ratchet shaft  23 . The purpose of this freely rotating gear  40  is to get the same rotational reference between the two tape take-up reels  34   a  and  34   b . The intermediate spur gear  40  meshes with another spur gear  41  mounted on the secondary tape rewind shaft  12 . The secondary tape rewind shaft  12  is attached to a second reel  34   b  to accept a second length of tape  5 . It will be appreciated by those skilled in the art that first gear  39  positioned on an opposing second end of said third shaft  30  and second gear  41  positioned on said second end of said second shaft  12  provide the drive mechanism with a means for transferring motion  44  from said third shaft  30  to said second shaft  12 . 
   While an embodiment has been illustrated and described in the drawings and foregoing description, such illustrations and descriptions are considered to be exemplary and not restrictive in character, it being understood that only an illustrative embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. The applicant has provided description and figures which are intended as an illustration of certain embodiments of the disclosure, and are not intended to be construed as containing or implying limitation of the disclosure to those embodiments. There are several advantages of the present disclosure arising from various features set forth in the description. It will be noted that alternative embodiment of the disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of the disclosure and associated methods that incorporate one or more of the feature of the disclosure and fall within the spirit and scope of the present disclosure as defined by the impendent claims.