Abstract:
A closure feed system for use on an associated form, fill and seal packaging machine for feeding and singulating closures from a closure storage region to a closure applicator. The feed system includes a chute for conveying the closures from the storage region to the applicator along a conveyance path defined by the chute. A singulator includes upper and lower reciprocating members configured for alternatingly reciprocating into and out of the conveyance path. The upper member includes a separating element having an upper surface and a lower surface. One of the upper and lower surfaces is formed at an incline relative to the other surface such that a distance between the upper and lower surfaces increases as the lower member moves into the conveyance path.

Description:
BACKGROUND OF THE INVENTION 
     The present invention pertains to a singulator for closures in a closure feed system. More particularly, the present invention pertains to a singulator for a closure feed system for use in a form, fill and seal packaging machine in which closure are mounted to the package. 
     Many of today&#39;s containers such as cartons are formed or made having spouts mounted thereto. For example, many of today&#39;s gable-top cartons include resealable spouts that are mounted to one of the gable panels to facilitate dispensing the contents from the carton and resealing the carton after use. 
     In the forming, filling and sealing operation of a packaging machine, the spouts must be mounted to the cartons in concert with the overall operation of the machine. To this end, these machines include applicator stations at which a spout is dispensed to an applicator and moved into contact with the carton. The applicator typically includes some form of sealing device, such as an ultrasonic sealing or welding head that moves into contact with the carton while the closure rests on an anvil that is also moved into contact with the carton. Energy is then transmitted from the sealing head into the carton material above the spout to seal the spout thereto. 
     In that many modern packaging machines operate at high speeds (some of which operate at speeds up to about 14,000 packages per hour), one concern is that the spouts or closures must be dispensed at a rate commensurate with the overall packaging machine speed, while accurately and precisely dispensing these closures for proper positioning within the applicator. It has been found that the spouts can clog or bottleneck in known dispensing arrangements thus slowing or requiring that the machine be shut down in order to free up the spouts at the dispensing location. A particular phenomena known as shingling occurs in which the thin closure flanges overlap one another and cause skewing of closures. This in turn causes the closures to jam within the feed system. 
     Typically, in closure feed systems, the spouts fall, by gravity, through a chute on to a reciprocating anvil in the applicator system. It has been found that shingling occurs and jams these systems, by clogging the chutes when more than one closure drops into position for receipt on the anvil. 
     Accordingly, there exits a need for a closure feed system that prevents the bottlenecking that may occur in the closure feed system. Desirably, such a closure feed system dispenses a single closure at a time for receipt by the anvil. More desirably, such a system singulates the closures or spouts for subsequent passage to and receipt on the applicator anvil. Most desirably, such a system singulates the closures and urges a lower closure from its adjacent upper closure for subsequent passage to the applicator anvil. 
     BRIEF SUMMARY OF THE INVENTION 
     A closure feed system for use on an associated form, fill and seal packaging machine feeds and singulates closures from a closure storage region to a closure applicator. The feed system overcomes known problems associated with closure shingling by urging the closures from one another and provides a force, over and above that of gravity to urge the closures, individually, to the closure applicator. 
     The feed system includes a chute for conveying the closures from the storage region to the applicator. The chute defines a conveyance path. The feed system further includes a singulator having upper and lower reciprocating members. In a preferred embodiment, the reciprocating members are formed as upper and lower plungers. The plungers are configured for alternatingly reciprocating into and out of the conveyance path. 
     The lower member includes a separating element having an upper surface and a lower surface. Preferably, the separating element is formed as a wedge. The lower surface of the wedge is formed at an incline or angle relative to the upper surface such that a distance between the upper and lower surfaces increases as the wedge moves into the conveyance path. 
     In a preferred embodiment, the angle between the upper and lower surfaces of the wedge is about 10 degrees to about 30 degrees. Most preferably, the angle is angle is about 20 degrees. The wedge can include a curved head portion and a concavity formed in the head to facilitate easing the wedge between adjacent, respective closures. 
     The reciprocating plungers can be first and second pneumatic cylinders for reciprocating the upper and lower reciprocating members. The cylinders and plungers can be mounted to a same side of the conveyance path to facilitate routing of pneumatic piping and/or tubing. 
     These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein: 
     FIG. 1 is a perspective view of an exemplary form, fill and seal packaging machine having a closure applicator system and a closure feed system embodying the principles of the present invention; 
     FIGS. 2 a  and  2   b  are perspective views of a closure feed system having a closure singulator embodying the principles of the present invention, the singulator being shown with closures positioned within the feed system chute, FIG. 2 a  illustrating the upper plunger in the extended position with a wedge positioned between adjacent, respective closures, and the with lower plunger in the retracted position, and FIG. 2 b  illustrating the upper plunger in the retracted position with the wedge removed from between adjacent, respective closures, and the with lower plunger in the extended position supporting the closures; 
     FIG. 3 is a view of the singulator system similar to that shown in FIGS. 2 a  and  2   b  the singulator system being shown without closures positioned therein for clarity of illustration; 
     FIG. 4 is an exploded view of the singulator system of FIG. 3; 
     FIGS. 5 a-d  are front and rear perspective views, a top view and a cross-sectional view of the wedge member of the present closure singulator system, FIG. 5 d  being taken along line  5   d — 5   d  of FIG. 5 c ; 
     FIG. 6 illustrates an exemplary closure that can be fed using the present closure feed system; and 
     FIG. 7 illustrates an alternate embodiment of the closure singulator system in which the wedge is mounted in an opposing manner to that shown in FIGS. 2-4. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated. It should be further understood that the title of this section of this application (“Detailed Description Of The Invention”) relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein. 
     Referring to the figures and in particular to FIG. 1, there is shown a typical form, fill and seal packaging machine  10 . The packaging machine  10  includes a closure feed system, indicated generally at  12 , embodying the principles of the present invention. A typical form, fill and sealing packaging machine  10  includes a carton magazine  14  for storing flat, folded cartons prior to erection. The machine  10  further includes a carton erection station  16 , a bottom flap sealing station  18  and a closure applicator station  20 . Subsequent to application of the closures, the carton may be sterilized, filled and subsequently sealed at a top panel sealing station  22  to form the well-known and well recognized carton gable-top. The cartons are then off loaded from the machine  10 . The construction and design of an exemplary machine is disclosed in Katsumata, U.S. Pat. No. 6,012,267, which patent is assigned to the assignee of the present invention and which patent is incorporated herein by reference for purposes of the that patent&#39;s disclosure of such a machine. 
     Referring now to FIG. 1, closures  24  are fed from a closure storage unit  26 , such as a bin, into the closure feed system  12 . As seen in FIGS. 2 a  and  2   b , the closure feed system  12  includes a plurality of rails  28 ,  30 ,  32 ,  34  that define a chute  36  for the closures  24 . A typical closure  24 , as illustrated in FIG. 6, includes a spout  38  that extends upwardly from one side  40  of a flange  42 . The flange  42  has a diameter d f  that is substantially larger than a diameter d s  the spout  38 . 
     Referring to FIGS. 2-3, in the chute  36 , the rails  28 - 34  bound the sides of the flange  42 , that reside on outer portions of the upper and lower surfaces of the flange  42  thus defining a pathway P for conveying the closures  24 . The closures  24  move through the chute  36  with the spouts  38  extending through an opening or gap between rails  28  and  30 , as indicated at  44 . 
     A singulator  46  includes a pair of reciprocating rods or plungers, shown as upper plunger  48  and lower plunger  50 . The plungers  48 ,  50  reciprocate in opposing manner to one another. That is, as seen in FIG. 2 b , when upper plunger  48  is in the retracted position, lower plunger  50  is in the extended position. Conversely, as seen in FIG. 2 b , when lower plunger  50  is in the retracted position, upper plunger  48  is in the extended position. The plungers  48 ,  50  extend into and retract from the closure conveyance path P, as defined by the chute  36 . 
     The upper plunger  48  is the stop for a line of closures that are within the chute  36 . The upper plunger  48  includes a plunger wedge  52  mounted thereto. As seen in FIGS. 5 a-d,  the plunger wedge  52  includes a first, generally horizontal upper surface  54  and a lower, angled or inclined surface  56 . A preferred inclined surface  56  is at an angle α of about 10 degrees to about 30 degrees to the upper surface  54 . In a present embodiment, the angle α is about 19 degrees. The line of closures  24  rest on the upper surface  54 . 
     The plunger wedge  52  is configured such that as it moves from the retracted position (FIG. 2 b ) to the extended position (FIG. 2 a ), i.e., into the closure pathway P, the distance d p  between the upper and lower surfaces  54 ,  56  increases. In this manner, as will be described below, as the plunger wedge  52  moves into or between respective upper and lower closures  24   b ,  24   a , the distance between the closures  24   b ,  24   a  increases, thus separating them to “unshingle” the flanges  42   b ,  42   a  from one another. For purposes of this discussion, the upper closure  24   b  is that closure that is to remain within the line of closures in the chute  36 , and the lower closure  24   a  is that closure that is to be dispensed to the applicator anvil (not shown). 
     The plunger wedge  52  can further include a rounded head portion  58 . In a current embodiment, the head  52  has a radius of curvature of about 3 millimeters (mm). The head  58  can further include a concave or recessed region  60  at the end thereof. The rounded head portion  58  and concavity  60  further facilitate easing the wedge  52  between the respective adjacent upper and lower closures  24   b ,  24   a , to reduce or eliminate the potential for crushing the closures  24   a ,  24   b  as the wedge  52  is urged between them. The wedge  52  can be secured to the plunger  48  by a pin  62  that inserts through an opening  64  formed in the body of the wedge  52 . 
     As set forth above, one of the problems encountered in currently known closure feed systems is that the flanges tend to shingle as the closures reside within the chute, between the rails. To this end, the present singulator  46  overcomes these problems by providing an additional force over and above that of gravity to help move the closures  24  through the chute  36 . 
     Referring to FIGS. 2 a  and  2   b , in operation, the plungers  48 ,  50  reciprocate in an opposing manner to one another. That is, as seen in FIG. 2 b , the lower plunger  50  is in the extended position while the upper plunger  48 , with the wedge  52 , is in the retracted position. In this manner, the closures  24   a ,  24   b  are prevented from falling through the chute  36  by the lower plunger  50 . Referring now to FIG. 2 a , the plunger positions are then reversed with the upper plunger  48  moving to the extended position between respective, adjacent upper and lower closures  24   b ,  24   a . As the upper plunger  48  moves to the extended position, the lower plunger retracts  50 . This permits the lower closure  24   a  to fall through the chute  36 . The upper surface  54  of the wedge  52  contacts a lower portion of the upper closure  24   b  to provide a stop to prevent the upper closure  24   b  (and those closures above it) from falling through the chute  36 . 
     At the same time, the lower, inclined or angled surface  56  of the wedge  52  contacts an upper portion of the lower closure  24   a . If the flanges  42   b ,  42   a  of the upper and lower closures  24   b ,  24   a  are shingled with one another, this could prevent the lower closure  24   a  from falling through the chute  36 . Continued extension of the upper plunger  48  urges the wedge  52  inwardly to separate the upper and lower closures  24   b ,  24   a  from one another, by pushing down on or urging the lower closure  24   a , thus “unshingling” the closure flanges  42   b ,  42   a . This, as will be understood from the drawings, urges the lower closure  24   a  down through the chute  36  thus singulating the closures  24 . 
     At this point in the operation cycle, the upper closure  24   b  is resting on the top surface  54  of the upper plunger wedge  52 , and the lower closure  24   a  has fallen through the chute  36  to the applicator anvil. The plunger  48 ,  50  positions then reverse, with the lower plunger  50  extending to support or prevent passage of the closures  24  and the upper plunger  48  retracting. The plungers  48 ,  50  then cycle once again with the lower plunger  50  retracting and the upper plunger  48  with the wedge  52  extending to singulate the next successive pair of adjacent closures  24 . 
     In a current embodiment, the plungers or rods  48 ,  50  are driven by pneumatic cylinders  66 ,  68 . The cylinders  66 ,  68  are connected to, i.e., plumbed from a common air source (not shown). It will, however, be recognized that the cylinders  66 ,  68  are connected to the air source in opposing relation to one another. That is, a feed line to one side of the upper plunger cylinder  66  will feed the opposite side of the lower plunger cylinder  68 . In this manner, the plungers  48 ,  50  are configured to cycle in opposing relation to one another. This may result in a “lag” in actuation of the plungers  48 ,  50  as a result of the reaction time of the plungers  48 ,  50  vis-à-vis the pneumatics of the cylinders  66 ,  68 . Other timing and/or coordination measures may be taken to assure that the closure feed system  12  is properly timed with the overall function and operation of the form, fill and seal packaging machine  10 . Those skilled in the art will also recognize the various other drive arrangements that can be used for the present feed system  12 , which other drive arrangements are within the scope and spirit of the present invention. 
     Referring now to FIG. 4, the plungers  48 ,  50  and cylinders  66 ,  68  are mounted to the feed system  12  by a mounting assembly  70  as will be readily recognized by those skilled in the art. The assembly  70  can include first brackets  72  mounted to upper and lower support plates  74 ,  76 . The plates  74 ,  76  have openings  78 ,  80  therein for passage of the closures  24 . Angle brackets  82  can be used to support the cylinders  66 ,  68 , and can be configured to permit readily adjusting the position of the cylinders  66 ,  68  and thus the plungers  48 ,  50  to permit accurate positioning of the plungers  48 ,  50  within the chute  36 . Other mounting arrangements will be readily recognized by those skilled in the art. It will also be recognized that although the cylinders  66 ,  68  are shown mounted to a common side of the chute  36 , this too can be modified for a desired machine configuration and design. 
     FIG. 7 illustrates an alternate embodiment of the singulator  146  in which the upper plunger  148  includes a wedge  152  that is mounted in opposing relation to that shown in FIGS. 2-4. That is, the wedge  152  is mounted upside-down with the inclined surface  156  oriented upwardly rather than downwardly. In this orientation, the inclined surface  156  urges the upper closure  24   b  upwardly to unshingle from the lower closure  24   a.    
     In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. 
     From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.