Patent Publication Number: US-2020290758-A1

Title: Method of packaging including covering an opening of a chute using a lid

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. patent application Ser. No. 15/845,334, filed Dec. 18, 2017, which is a continuation application of U.S. patent application Ser. No. 13/666,485, filed Nov. 1, 2012, which claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 61/554,303, filed on Nov. 1, 2011, the entire contents of each of which are incorporated herein by reference. 
    
    
     WORKING ENVIRONMENT AND PROBLEM ADDRESSED 
     Smokeless tobacco products can be packaged and sold in round metal, plastic or paperboard cans which have removable metal or plastic lids. A new development is to package smokeless tobacco products, including pouched MST (snus) in hinge-lid boxes. 
     Machine handling of snus during packaging presents difficulties, because of its tackiness and pillow shape. Boxing operations may include placement of a desired portion (or lot or quantity) into a bag and then placing the bag into a box or other container. 
     The use of bags requires establishment of “head room” in the bag so that product is not caught in sealing of the bag at its top. The presence of head room in the box creates an impression upon opening of the box being only partially filled and frustrates easy removal of the first several pieces. The latter is particularly true for small boxes such as those which are to be used with snus. 
     It is desirable to achieve packaging methods and articles which avoid a need for head room and its disadvantages. 
     SUMMARY 
     In a preferred embodiment, an apparatus for high speed packaging of loose product is provided. The apparatus comprises a loading station, a box forming station, and an unloading station. The loading station includes chutes in spaced apart relation. Each chute has an open top, an open upstream end, and an open downstream end. The open top is configured to receive loose product while moving along a first feed path. 
     The box erecting apparatus is operable to erect boxes in spaced apart relation with first and second open sides and align the first open side of each box with the open downstream end of a corresponding chute while traveling along a second feed path, which is parallel to the first feed path. 
     The unloading station includes a stationary vacuum head in communication with the second open side of each box. The vacuum head provides a continuous vacuum source along the second feed path. Preferably, the unloading station also includes a plunger in communication with the open upstream end of the chute. Loose product is transferred from the chute through the open downstream end and to the box at the unloading station. 
     In the preferred embodiment, the apparatus can also include a lid operable to cover the open top of each chute when positioned at the box erecting apparatus. Also preferably, the lid includes at least one air inlet operable to deliver air from a pressurized air source to each chute so as to agitate any remaining loose product contained in the chute and urge the loose product from the chute. 
     Preferably, an inner surface of the chute includes a non-stick coating. The vacuum head includes a screen having openings sized to substantially prevent suction of loose products into the vacuum head. Preferably, the plunger moves reciprocally from a first upstream position to a second downstream position when aligned with the open upstream end of the chute. Also preferably, the loading station includes cups operable to dump loose product into the open top of the chute. 
     In the preferred embodiment, the box erecting apparatus further includes a conveyor for moving boxes along the second feed path. Preferably, the box erecting apparatus also includes a support bar operable to hold erected boxes open while traveling along the second feed path. 
     In another preferred embodiment, a method of loading boxes with loose products is provided. The method includes loading loose products into chutes in spaced apart relation. Each chute has an open top, an open upstream end, and an open downstream end. The open top is operable to receive loose product while moving along a first feed path. The method also includes aligning boxes in spaced apart relation, each box having a first and second open side, and aligning the first open side of each box with the open downstream end of a corresponding chute while moving the boxes along a second feed path. The second feed path is parallel to the first feed path. The method can also include unloading loose product from each chute into a corresponding box by communicating vacuum through the second open side of each box so as to pull loose product from the chute and into the box. 
     Preferably, the method can also include advancing a plunger through the upstream end of the chute, through the downstream end of the chute, and into the corresponding box thereby assuring a complete transfer of loose product to the box. In the preferred embodiment, the method can include covering the open top of each chute with a lid prior to applying suction and providing at least one air inlet in the lid operable to deliver air from a pressurized air source to each chute. Also preferably, the plunger is plunged about 2 mm to about 4 mm into the erected box. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a flow diagram of an apparatus and method for loading pouch products in boxes. 
         FIG. 2  is a top view of an apparatus for loading pouch products in boxes. 
         FIG. 3  is perspective view of a chute for use with the apparatus of  FIG. 2 . 
         FIG. 4  is a top view illustrating the path of the plungers shown in  FIG. 2 . 
         FIG. 5  is a front view of the vacuum head for use in the apparatus of  FIG. 2 . 
         FIG. 6  is an illustration showing a box blank being partially erected at a box erecting station as described herein. 
         FIGS. 7A and 7B  are illustrations of the chute loading station utilizing a cup transport system as described herein. 
         FIG. 8  is an illustration of further packaging steps that can be performed at the further packaging station of  FIG. 1 . 
         FIG. 9  is an illustration of the unloading station of  FIG. 1 . 
         FIG. 10  is a perspective view of an individual cup of the preferred embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     In the preferred embodiment, as shown in  FIG. 1 , a snus forming and packaging system  101  is provided which preferably comprises a chute (or bucket) loading station  30 , a box erecting station  40  and a chute unloading station  50 . Preferably, loose product  122  (shown in  FIG. 2 ) is loaded into chutes at the chute loading station  30 , boxes are at least partially erected at the box erecting station  40 , and the loose product  122  is transferred from each chute into a corresponding box at the chute unloading station  50 . 
     In the preferred embodiment, the loose product  122  comprises oral tobacco or non-tobacco pouch products such as those described in commonly-owned U.S. Pat. No. 7,980,251 issued Jul. 19, 2011 and U.S. Pat. No. 7,950,399 issued May 31, 2011, the entire content of each of which is incorporated herein by this reference thereto. 
     Preferably, the pouch products are formed at a pouch forming apparatus  10 , which can be a high speed vertical form, fill and seal apparatus or other suitable pouch forming apparatus. In the preferred embodiment, the pouch forming apparatus such as a vertical filling machine obtainable from Merz Verpackungmachinen GmbH of Germany. Other suitable machines may be sourced from Ropak Manufacturing Company of Alabama, USA, among others. 
     After formation, the pouch products are moved to a pouch dispenser  20 , which dispenses a predetermined quantity of pouch products into individual cups  225  (shown in  FIGS. 7A, 7B and 10 ). Preferably, the predetermined quantity is chosen to coincide with the number of pouch products to be placed in an individual consumer package. In the preferred embodiment, the pouch dispenser  20  comprises the dispenser provided on the Merz machine. 
     Referring now to  FIG. 10 , the cup  225  preferably comprises a cupped body constructed of a hard plastic of proportions akin to those of a bottom portion of a commercially available snus can (such as in the packaging of loose moist snus tobacco). Such configuration of the cup  225  promotes compatibility of the cup  225  with snus loading and canning machines and associated conveyors. In the preferred embodiment, each cup  225  is provided with an annular recess  297 , preferably adjacent its base, although other locations might be practiced. Each cup  225  is opened at its top  299  and provides sufficient volume to receive a predetermined, desired count (or lot) of snus product. 
     In the preferred embodiment, the cups  225  move to the chute loading station  30  via a cup transport system. A suitable cup transport system is a hook type system shown in  FIGS. 7A and 7B . As shown in  FIG. 7A , cups  225  loaded with loose product are transported to the cup transport system where a star wheel  500  pushes each cup  225  into position for pickup by a hook  227 . Each cup  225  can be picked up around a periphery  226  thereof by the hook  227  and carried along a third feed path  502  which is parallel to and directly above a first feed path  4  on which the chutes  120  travel as shown in  FIG. 7B . Preferably the hooks  227  are sized to releasably engage each cup  225  at its recess  297 . Preferably, multiple hooks  227  are attached to a conveyor  504  that travels horizontally in a continuous loop in a path resembling a racetrack. However, other suitable arrangements are possible. 
     The star wheel  500  preferably moves continuously and includes a plurality of claws  501 , each of which engages a trailing side of a cup  225  as the latter is released from the inclined chute  505  by retraction of a pin  506 , whose retraction is synchronized with the rotation of the wheel  500 . A rail (guide)  508  guides each cup  225  into an intersecting relation with an arriving hook  227 . The end portion  510  of the rail  508  is spaced from working surfaces of the wheel  500  such that the respective cup  225  is momentarily held in slight compression so that the arriving hook  227  engages and clasps the cup  225  about its recess  297  ( FIG. 10 ). A biased detent at the base of the hook  227  assures a releasable retention of the cup  225  on the hook  227 . 
     Preferably, the hooks  227  flip the cups  225  sequentially, one at a time, as each cup  225  is positioned above a chute  120  to dump loose product  122  into an open top  124  of the chute  120  positioned beneath and continuously moving with the cup  225 . The empty cups are returned to the pouch dispenser  20  and filled again. Alternatively, the pouch products can be moved to the chute loading station  30  by other methods and arrangements. For example, a predetermined quantity of pouch products can be placed directly from the pouch forming apparatus  10  directly into the chute  120  at the chute loading station  30 . Arrangements with trap doors and other expedients are also envisioned. 
     At the chute loading station  30 , a plurality of a chutes  120  move horizontally along a continuous loop such that each chute  120  is repeatedly loaded with loose product at the chute loading station  30  and unloaded at the unloading station  50 . In the preferred embodiment, the chutes  120  travel in spaced apart relation along the first feed path  4  and are releasably attached to a conveyor that travels horizontally along a rectilinear path at the chute loading station  30  and the chute unloading station  50 . Once the chutes  120  are unloaded at the unloading station  50 , the conveyor turns downwardly so as to return the chutes  120  to the chute loading station  30 . 
     Preferably, each chute  120  (shown in  FIGS. 2 and 3 ) is loaded with the loose product from a single cup  225  (shown in  FIG. 7 ). The chute  120  then moves along the first feed path  4  to the chute unloading station  50  where the loose product is transferred from the chute  120  into a corresponding box  44 . 
     As shown in  FIG. 3 , each chute  120  has an open top  124 , an open upstream end  126 , and an open downstream end  128 . The open top  124  is sized and configured to allow for placement of loose product  122  into the chute  120  at high speed as the chute moves along the first feed path  4  and the cup  225  moves along the third feed path  502 . Moreover, the open top  124  can include substantially vertical sidewalls  164  extending around the periphery of the open top  124  and inclined end walls  125 ,  127 . The sidewalls  164  can be formed at an angle so as to form a funnel through which the loose product  122  travels as it enters the chute  120 . Moreover, the sidewalls  164  can be preferably about 0.5 inch to about 3.0 inches in height. 
     Preferably, the inner surface  220  of each chute  120  includes a non-stick coating so as to substantially prevent loose product from sticking to the inner surface  220  of the chute  120 . Preferably, each chute  120  is releasably attached to its conveyor to facilitate removal for cleaning. 
     As noted above, loose product  122  is released into the open top  124  from a corresponding cup  225  as the cup  225  travels in a superposed relation to a respective chute  120 . In the preferred embodiment, each cup  225  and a respective chute  120  are superposed and travel at the same speed. Thus, the cups  225  travel along a linear path (the third feed path  502 ), which is parallel to the first feed path  4  along which the chutes  120  travel. The apparatus is arranged such that each cup  225  is flipped over to release product while a chute  120  is aligned beneath the cup  225 . 
     Referring now to  FIG. 7B , each hook  227  preferably is subject to the action of a cam follower  851 ; which when progressed into a recess  853  of the guide  855 , causes the hook  227  to flip. The cup  225  then continues along in an upside down relation with the hook  227  now leading the cup  225 . This relationship is maintained until the cup  225  is plowed off the hook  227  by a rail or other suitable contrivance onto a conveyor, which returns the cups  225  to the pouch dispenser  20  in an upside down condition. Return conveyance in an upside-down condition avoids collection of dust or dirt and assures emptiness for the next loading cycle. The pouch dispenser  20  includes a rail to flip each cup  225  into right-side up orientation prior to reloading of the cup  225 . 
     At or about the same time as the chute  120  is loaded with loose product  122 , a box  44  (shown in  FIG. 2 ) is at least partially erected at a box erecting station  40 . In the preferred embodiment, each box  44  is a side-loading, inner box such as that described in commonly-owned Non-Provisional patent application Ser. No. 13/325,803 filed Dec. 14, 2011, the entire content of which is incorporated herein by reference thereto. Alternatively, the box  44  can be loaded via a top or bottom openings or the box  44  can be an outer box. 
     In the preferred embodiment, the box blank is in a flattened condition, with top and front panels superimposed over and connected with bottom and back panels, and with dust flaps  159  and side flaps  160  disposed within the general plane of the flattened blank. 
     Preferably, a rotary blank feed  42  feeds box blanks from a hopper  43 . Each blank  162 , as shown in  FIGS. 2 and 6 , is erected to form a box  44  along a second feed path  8 , which is substantially parallel to the first feed path  4 . Once the box  44  is erected, plows and tuckers open the dust flaps  159  and the side flaps  160  outwardly to expose a first open side  150  and a second open side  152 . The erected box  44  then moves along the second feed path  8  to the chute unloading station  50 . 
     In the preferred embodiment, the box erecting station  40  further includes a conveyor  400  (shown in  FIG. 2 ) for moving boxes  44  along the second feed path  8 . Preferably, the box erecting apparatus also includes a support bar  560  (shown in  FIG. 9 ) which is operable to hold erected boxes  44  open while traveling along the second feed path  8 . 
     Preferably, the second feed path  8  travels substantially parallel to and at the same speed as the first feed path  4  so that each box  44  has a corresponding chute  120  with which to mate at the chute unloading station  50 . Thus, at the chute unloading station  50 , the second open side  152  of the box  44  is aligned with a downstream end  128  of the chute  120  and the first open side  150  of the box is in contact or proximate with a face  100  of a vacuum head  200  which receives vacuum from vacuum source  102 . 
     Referring now to  FIGS. 2 and 9 , once the chutes  120  reach the chute unloading station  50 , the chutes  120  travel under a stationary lid  105 , which may contact upper edges  95  of the open top  124  and/or sidewalls  164  of the chute  120 . Typically, the lid  105  does not form a seal, but does substantially close off the open top  124  of the chute  120 . Preferably, the lid  105  includes multiple spaced apart air inlets  110 , each of which lines up with the open top  124  of a chute  120  as it passes underneath the lid  105 . Preferably, the air inlets  110  are connected to a pressurized air source  112 , which provides a pulse of air to the chute  120 . Preferably, the pulse of air is timed with alignment of the chute  120  underneath the air inlet  110 . The pulse of air agitates the loose product  122  disposed within the chute  120  as vacuum is applied so as to ensure that the entire predetermined quantity of loose product  122  is transferred from the chute  120  into the confines of the opened box  44 . The agitation also assures that product does not form a blocking mass of product or “bridges” the chute  120 . Agitation can be achieved instead by or supplemented with mechanical arrangements (e.g., vibratory plates or pins) or electro-mechanical arrangements such as with ultrasonic devices. The pulses of air of the preferred embodiment are preferably at or about approximately 2 or 3 psi, when packaging snus. 
     Also preferably, the unloading station  50  includes a stationary vacuum head  200  in communication with the second open side  150  of each box  44 . The vacuum head  200  in the preferred embodiment is about 1 foot to about 4 feet in length when packaging pouched snus and each box  44  travels along the length of the vacuum head  200  while suction is applied. 
     In the preferred embodiment, a source of vacuum  102  comprises a vacuum pump connected to the vacuum head (plenum)  200  to provide a continuous vacuum source along the second feed path  8 . When packaging pouched snus, the vacuum pump preferably is capable of drawing air at a rate in the range of approximately 300 to 500 cubic feet per minute. In practice, a vacuum pump of 10 horsepower with a rating of 420 cfm and capability to draw vacuum of 100 inches of water should suffice for snus product. Such arrangement provides sufficient vacuum to the product through the vacuum head  200  at the second open side  150  of each box  44  so as to pull loose product  122  from the chute  120  into the interior of each box  44 , essentially without compressing the product. 
     In the preferred embodiment, as shown in  FIG. 5 , the vacuum head (plenum)  200  has a face  100  which includes a screen  201  having openings sized to substantially prevent suction of loose product  122  into the vacuum head  200  as vacuum is applied. 
     Preferably, the vacuum plenum  200  is located downstream of where loose product  122  is released from a cup  225  into a chute  120 . Preferably, agitation of product occurs as vacuum begins to be communicated through the chute  120  to the product  122 . 
     In the preferred embodiment, about three chutes  120  are unloaded at a time. However, more or fewer chutes  120  could be unloaded at a time depending upon the length of the vacuum head  200  and the spacing between the chutes  120 . 
     Also in the preferred embodiment, as shown in  FIG. 2 , the open upstream end  126  of the chute  120  is sized to accept a plunger  114  therethrough. Preferably, the apparatus includes a plurality of plungers  114 , which travel along a fourth feed path  522 . In the preferred embodiment there are three plungers. The plungers  114  are reciprocal and move forward to position B′ (shown in  FIG. 4 ) after suction has been applied and the loose product  122  has substantially been moved from the chute  120  and into the box.  44 . Each plunger  114  moves forward and through each corresponding chute  120  such that the plunger  114  enters the corresponding box  44  only slightly, preferably only about 2 mm to about 4 mm. The plungers do not travel further into the box  44  to avoid compression of the loose product  122 . After moving into the box  44 , the plunger  114  then moves with the chute  120  to position B″ before moving out of the chute  120  to position B′″ and finally back to initial position B″″ where the plunger  114  waits for the next corresponding chute  120 . The three plungers of the preferred embodiment move with the chutes to which they correspond and move together to return to position B. Action of the plungers assures clearance of product from the chutes  120  and complete delivery into the interior spaces of the opened boxes. 
     Once the box  44  is filled with loose product  122 , the box dust and side and flaps  159 ,  160  are optionally glued and folded at the box folding station  60  to close and optionally seal the box  44 . The box  44  is then inspected at the box inspection station  70  to check for holes, improper seals, and the like. 
     As shown in  FIG. 8 , the box  44  can then travel to the further packaging station  80 , where the box  44 , can be placed in an outer box  82 . In addition, overwrap can be applied to the outer box  82  to maintain freshness of the loose product  122 . The overwrap can be formed of any suitable plastic or foil material. Meanwhile, the cups  225  used to deliver loose product  122  to the chutes  120  are returned via empty cup return  90  to the pouch dispenser  20 . 
     By such arrangement as described above, snus and other loose product may be loaded into a box or other container with a more complete, uniform, homogeneous and efficient disposition of the loose product within the container. Undesirable and troublesome headspace is avoided. Smaller containers can be used for the same amount of product, which may lead to significant savings in packaging materials and space requirements in displaying product at retail. The arrangement provides high speed production capability, particularly with boxing of pouched snus product. 
     In another preferred embodiment, a method of filling or loading boxes with loose product(s) is provided. Broadly speaking, the method includes establishing a procession of package structures, each of which has first and second openings and an interior space or volume. Establishing the procession of package structures may also include folding open flaps of a package. In addition, the method includes repetitively establishing predetermined quantities of loose product and repetitively disposing said quantities at locations adjacent said first openings. That repetitive disposition of quantities may include loading loose products into chutes in spaced apart relation. Each chute has an open top, an open upstream end, and an open downstream end. The open top is operable to receive loose product while moving along a first feed path. The method also includes aligning boxes in spaced apart relation, each box having a first and second open side, and aligning the first open side of each box with the open downstream end of a corresponding chute while moving the boxes along a second feed path. Preferably, the second feed path is parallel to the first feed path. 
     Also preferably, the method includes transferring or unloading disposed quantities of loose product from each chute into the interior space of a corresponding box by applying or communicating a vacuum through the second open side of each box so as to pull loose product from the chute and into the box. The transferring step may further include moving the open package along a vacuum plenum. 
     Preferably, the step of transferring of loose product by communicating a vacuum includes agitating the loose product while applying vacuum. In the preferred embodiment, the method can include covering the open top of each chute with a lid as or prior to applying vacuum and providing at least one air inlet in the lid operable to deliver air from a pressurized air source to each chute to agitate product as vacuum is applied. 
     Preferably, the method can also include purging the chute or passage or errant product by advancing a plunger through the upstream end of the chute, through the downstream end of the chute, and into the corresponding box thereby assuring complete transfer of loose product to the box. Preferably the plunger is advanced into the interior of the box slightly, such that mechanical compression of product is avoided or minimized. Also preferably, the plunger is plunged only about 2 mm to about 4 mm into the erected box. 
     When the product has been loaded into the box, the method also includes closing the first and second openings of the box. 
     In this specification, the word “about” is often used in connection with numerical values to indicate that mathematical precision of such values is not intended. Accordingly, it is intended that where “about” is used with a numerical value, a tolerance of ±10% is contemplated for that numerical value. 
     While the foregoing describes in detail an apparatus and method for packaging loose product with reference to a specific embodiment thereof, it will be apparent to one skilled in the art that various changes and modifications and equivalents to the apparatus and method may be employed, which do not materially depart from the spirit and scope of the invention.