Patent Publication Number: US-2003231922-A1

Title: Arrangement for making textured multi film solid cleanser holders

Description:
CLAIM OF PRIORITY  
       [0001] This application claims priority to Indian Patent Application No. 413/MUM/2002 filed May 7, 2002, the disclosure of which is hereby incorporated by reference.  
       [0002] 1. Field of Invention  
       [0003] This invention relates to an arrangement for making textured multi film solid cleansers holders  
       [0004] 2. Prior Art  
       [0005] U.S. patent application Ser. No. 09/503262 filed on Jun. 13, 2001 relates to textured film solid cleanser holders and methods for the manufacture and use thereof. A textured film solid cleanser holder comprises a solid cleanser surrounded by at least one textured film having texture variations including at least one aperture.  
       OBJECTS OF INVENTION  
       [0006] An object of the invention is to provide an arrangement for making textured multi film solid cleanser holders.  
       [0007] Another object of the invention is to provide an arrangement for making frilled textured multi film solid cleanser holders.  
       DESCRIPTION OF INVENTION  
       [0008] According to the invention there is provided an arrangement for making textured multi film solid cleanser holders comprising a solid cleanser feed conveyor horizontally rotatably mounted on a first frame work and provided with a plurality of spaced solid cleanser holding pockets along the length thereof, a film feeding unit comprising at least one pair of film unwind top rolls and at lest one pair of film unwind bottom rolls rotatably mounted on a stand at the feed end of the feed conveyor, a pair of film lamination units each mounted at the top and bottom of the first framework, a solid cleanser holder forming unit comprising a pair of horizontally contrarotatable conveyors disposed spaced one below the other and mounted on a second framework which is located close to the discharge end of the feed conveyor, a solid cleanser holder sealing unit, a solid cleanser holder cutting unit, a film scoring unit and a horizontally rotatable waste film carrying conveyor mounted on the second frame work in tandem with the solid cleanser holder forming unit and a plurality of film tensioning rollers and a plurality of film pulling units provided in the path of the textured and an intermittent differential drive unit connected To the feed conveyor, contrarotatable conveyors, film scoring unit, waste film carrying conveyor and film pulling units.  
       [0009] The term textured film and texture variations as used in the specification have the same meanings as given in the U.S. patent application Ser. No. 09/503262  
       [0010] The solid cleanser referred to in the specification may be a soap or detergent cake or bar. 
     
    
    
     [0011] The following is a detailed description of the invention with reference to the accompanying drawings, in which:  
     [0012]FIG. 1 is elevation of an arrangement for making textured multi film solid cleanser holders according to an embodiment of the invention;  
     [0013]FIG. 2 is enlarged elevation of a film lamination unit of the arrangement of FIG. 1;  
     [0014]FIG. 3 is isometric view of a movable laminator plate or stationary laminator plate of the film lamination unit of FIG. 2  
     [0015]FIG. 4 is enlarged elevation of the solid cleanser holder sealing unit of the arrangement of FIG. 1  
     [0016]FIG. 5 is front view of the movable die plate or stationary die plate of the solid cleanser holder sealing unit of FIG. 4  
     [0017]FIG. 6 is enlarged elevation of the solid cleanser holder cutting unit of the arrangement of FIG. 1;  
     [0018]FIG. 7 is front view of the movable punch plate of the solid cleanser holder cutting unit of FIG. 6;  
     [0019]FIG. 8 is an enlarged view at X in FIG. 6  
     [0020]FIGS. 9 &amp; 10 are elevation and side view of the film scoring unit of the arrangement of FIG. 1  
     [0021]FIGS. 11 &amp; 12 are elevation and side view of a film pulling unit of the arrangement of FIG. 1  
     [0022]FIG. 13 is schematic view of the intermittent differential drive unit of the arrangement of FIG. 1;  
     [0023]FIG. 14 is schematic view of the pneumatic view of the pneumatic cylinders of the film lamination units, solid cleanser holder sealing unit and solid cleanser holder cutting unit of the arrangement of FIG. 1 connected to a pneumatic supply through 5-port 2-position solenoid operated direction control valves, and  
     [0024] FIGS. ,  15 .,  16 ,  17 ,  18   7   19  show the various positions of the Geneva drive in a cycle of operation of the arrangement of FIG. 1; and  
     [0025]FIG. 20 is cross section of a multi film solid cleanser holder made by the arrangement of FIG. 1 
    
    
     [0026] As illustrated in FIGS.  1  to  20  of the accompanying drawings, the arrangement  1  comprises a solid cleanser feed conveyor  2  horizontally rotatably mounted on a first frame work  3  and provided with a plurality of spaced solid cleanser holding pockets along the length thereof (FIG. 1). Each of the solid cleanser holding pockets comprises a pair if spaced upright members  4  fitted across the length of the feed conveyor. A pair of film unwind top rolls  5 , 5  and a pair of film unwind bottom rolls  6 , 6  and rotatably mounted on a stand  7  at the feed end  8  of the feed conveyor.  9 , 9  represent the shafts of the film unwind top rolls.  10 ,  10  represent the shafts of the film unwind bottom rolls.  11   a  and  11   b  are a pair of film lamination units, each mounted at the top and bottom of the first framework  3 . Each of the film lamination units comprises a first pneumatic cylinder  12  mounted on the top horizontal member  13  of a first supporting structure  14  and having a first piston  15  reciprocating therein (FIGS. 2 and 3). The first piston rod  16  protrudes down from the first cylinder through the top horizontal member of the first supporting structure. Air inlets cum outlets at the cylinder side and piston side of the first cylinder are marked  17  and  18  respectively. The cylinder side and piston side of the first pneumatic cylinder are connected to a pneumatic supply  19  through 5 port 2 position solenoid operated direction control valve  20  and a control valve  21  (FIG. 14). The 5 ports of the valve  20  are marked a,b,c, d &amp; e. The solenoid of the valve  20  is marked  22 .  23  is a movable laminator plate fitted to a first guide plate  24  which in turn is fitted to the protruding end of the first piston rod (FIGS. 1 &amp; 2). The first guide plate is up and down slidably engaged over guide rods  25  of the first supporting structure through bushes  26  fitted to the guide plate.  27  is a stationary laminator plate fitted at the base  28  of the first supporting structure aligned with the movable laminator plate. Both the movable laminator plate and stationary plate are provided with a pair of spaced laminating ridges  29  across the length thereof (FIG. 3). Both the movable laminator plate and stationary plate are also provided with electric heating elements comprising conductors  30  running therethrough and connected to an AC supply (not shown) through thermostat (not shown) and temperature controller (not shown).  31  is a solid cleanser holder forming unit comprising a pair of horizontally contrarotatable conveyors  32  &amp;  33  disposed spaced one below the other and mounted on an upright structure  34  of a second framework  35  which is located close to the discharge end  36  of the feed conveyor (FIG. 1). The bottom and top rollers at the feed end  37   a  and discharge end  37   b  of the contrarotatable conveyors are marked  38   a  and  38   b  and  38   c  and  38   d  respectively. The shafts of the rollers  38   a ,  38   b ,  38   c , &amp;  38   d  are marked  39   a ,  39   b ,  39   c , &amp;  39   d  respectively. The first framework  3  is provided with a flat protrusion  40  at the discharge end  36  of the feed conveyor extending to the feed end  37   a  of the contrarotatable conveyors.  41  is a solid cleanser holder sealing unit mounted on the second framework  35  and comprising a second pneumatic cylinder  42  mounted on the top horizontal member  43  of a second supporting structure  44  and having a second piston  45  reciprocating therein (FIGS. 1 &amp; 4). The second piston rod  46  protrudes down from the second cylinder through the top horizontal member of the second supporting structure. Air inlets cum outlets at the cylinder side and piston side of the second cylinder side are marked  47  and  48  respectively. The cylinder side and piston side of the second cylinder are connected to the pneumatic supply through a 5 port 2-position solenoid operated direction control  49  and control valve  21  (FIG. 14). The 5 ports of the valve  49  are marked a, b, c, d &amp; e. The solenoid of the valve  49  is marked  50 .  51  is a movable die plate fitted to a second guide plate  52  which in turn is fitted to the protruding end of the second piston rod and up and down movable engaged over guide rods  53  of the second supporting structure through bushes  54  fitted to the guide plate  52 .  55  is a stationary die plate fitted at the base  56  of the second supporting structure aligned with the movable die plate. The movable die plate  51  and stationary die plate  55  are formed with die sockets  57  corresponding to the size of the solid cleanser holders and provided with electric heating elements comprising conductors  58  around the sockets and connected to the AC supply through thermostat (not shown) and temperature controller (not shown).  59  is a solid cleanser holder cutting unit mounted on the second framework  35  and comprising a third pneumatic cylinder  60  mounted on the top horizontal member  61  of a third supporting structure  62  and having a third piston  63  reciprocating therein (FIGS. 1 &amp; 6). The third piston rod  64  protrudes down from the third cylinder through the top horizontal member of the third supporting structure. Air inlets cum outlets at the cylinder side and piston side are marked  65  &amp;  66  respectively. The cylinder side and piston side of the third cylinder are connected to the pneumatic supply through 5 port 2-position solenoid operated direction control valve  67  and control valve  21  (FIG. 14). The five ports of the valve  67  are numbered a,b,c,d &amp; e. Solenoid of the valve  67  is marked  68 .  69  is a movable punch plate fitted to a third guide plate  70  which in turn is fitted to the protruding end of the third piston rod and up and down slidably engaged over guide rods  71  of the third supporting structure through bushes  72  fitted thereto. The movable punch plate is provided with a pair of holes  73  defining neck portions  74  (FIG. 8).  75 ,  75  are a pair of screw members each being movably disposed in each of the holes with the heads of the screw members adapted to abut against the shoulders  77  of the neck portions (FIG. 8 ).  78  is a retainer flange provided at the front side of the punch plate in thread engagement with the edges of the screw. Members. The film retainer flange is held stressed by tension springs  79  disposed over the screw members and located between the punch plate and the film retainer flange.  80  is a stationary die plate fitted at the base  81  of the third supporting structure aligned with the movable punch plate. The movable punch plate and stationary die plate are formed with die cavities  82  which are larger than the die sockets in the movable die plate and stationary die plate of the solid cleanser holder sealing unit and are corresponding to the profiles of the edges or frills of the solid cleanser holders. The bottom of the die cavity  82  in the stationary die plate  80  is open.  83  is an opening in the base of the third supporting structure corresponding to the open bottom die cavity in the stationary die plate  80 .  84  us a film scoring unit mounted on the second framework  35  and comprising an anvil roller  85  whose shaft  86  is rotatably supported in a pair of first vertical oblong slots  87  provided in a pair of spaced first vertical side plates  88  of a fourth supporting structure  89  (FIGS. 1, 9 &amp;  10 ). The bearings  90  of the anvil roller shaft are located at the bottom of the first vertical oblong slots. Therefore, the anvil roller remains in position.  90   a  is a driver gear fitted on the shaft  86  at its one end.  91  is a rotary disc cutter disposed across and close to the anvil roller and having its shaft  92  fitted with bearings  93  mounted in the first vertical oblong slots in the first vertical plates.  93   a  is a driven gear fitted on a shaft  92  at its one end. Gears  90   a  and  93   a  are in mesh with each other (FIG. 9). The bearings  93  are stressed by tension springs  94  in abutment with first setting screws  95  secured through the top horizontal member  96  of the fourth supporting structure in thread engagement therewith. The first setting screws are provided with first lock nuts  97 . The clearance between the rotary disc cutter and the anvil roller is adjusted by moving the rotary cutter down by turning and moving down the setting screws against the tension springs and stressing or compressing the tension springs. The setting screws are locked in position with the lock nuts against the horizontal member of the fourth supporting structure.  98  is a horizontally rotatable waste film carrying conveyor mounted between a pair of upright members  99  of the second framework  35 . Only one of the upright members is seen in FIG. 1 as the other is behind the one shown in FIG. 1. The solid cleanser holder sealing unit, solid cleanser holder cutting unit, film scoring unit and film carrying conveyor are in tandem with the solid cleanser holder forming unit.  100  represents a plurality of film tensioning rollers.  100   a ,  100   b ,  100   c , &amp;  100   d  represent a pluralirty of film pulling units (FIG. 1 ). Film pulling unit  100   a  is mounted on the upright structure  34 . Firm pulling units  100   b  &amp;  100   c  &amp;  100   d  are mounted directly on the second framework  35 . Each of the film pulling units  100   a ,  100   b ,  100   c  &amp;  100   d  comprises a pair of horizontally contrarotatable rollers  101  &amp;  102  disposed one below the other in contact (FIGS. 11 &amp; 12). The shaft  103  of the bottom roller  101  is fitted with bearings  104  at the ends thereof which are located in a pair of second vertical oblong slots  105  provided in a pair of spaced second vertical side plates  106  of a fifth supporting structure  107 . The bearings  104  of the shaft  103  are located at the bottom of the oblong slots  105 . Therefore, the bottom roller  101  remains in position.  104   a  is a driver gear fitted at one end of the shaft  103 . The shaft  108  of the top roller  102  is fitted with bearings  109  at the ends thereof which are located in the second vertical oblong slots  105 .  109   a  is a driven gear fitted at one end of the shaft  108 . Gears  104   a  and  109   a  are in mesh with each other (FIGS.  11   7   12 ).  110 ,  110  are pair of second setting screws whose edges are in contact with the bearings  109 . The second setting screws  110  are secured through the top horizontal member  111  of the fifth supporting structure in thread engagement therewith. The second setting screws are provided with second lock nuts  112 . The clearance between the top roller and bottom roller is adjustable by turning and moving down the second setting screws against the tension springs and stressing or compressing the tension springs. The second setting screws are locked in position with the locknuts against the horizontal member of the fifth supporting structure.  113  is a geared motor whose shaft is marked  114 .  115  is a six station Geneva drive compressing a Geneva wheel  116  and a Geneva driver  117 . Geneva wheel shaft is marked  118 . Six slots of the Geneva wheel are marked  119   a ,  119   b ,  119   c ,  119   d  and  119   f . Geneva driver shaft is marked  120 .  121  is pinion of the Geneva driver.  122  &amp;  123  are sprockets mounted on the motor shaft and Geneva driver shaft, respectively and interconnected by chain  124 . The teeth ratio of sprockets  122  and  123  is 2:3.  125  is a sprocket mounted on the Geneva wheel shaft  126 ,  127 ,  128 ,  129  &amp;  130  are sprockets mounted on the shaft  39   c  of roller  38   c  of conveyor  33 . Sprockets  125  and  128  are interconnected by chain  132 .  133  is a driver roller shaft of the feed conveyor  2 .  134  is a sprocket mounted on the drive roller shaft  133 . Sprockets  126  and  134  are interconnected by chain  135 .  136  is a sprocket mounted on the driver shaft  137  of the film pulling unit  100   a . Sprockets  129  and  136  are interconnected by chain  138 .  139  is a sprocket mounted on the driver shaft  140  of the film pulling unit  100   b . Sprockets  130  and  139  are interconnected by chain  141 .  142  &amp;  142  are sprockets mounted on the driver shaft  144  of the film pulling unit  100   c . Sprockets  127  &amp;  143  are interconnected by chain  145 .  146 ,  147  &amp;  148  are sprockets mounted on the driver shaft  149  of the film pulling  100   d . Sprockets  142  and  146  are interconnected by chain  149 .  150  is a sprocket mounted on the driver shaft  151  of the waste film carrying conveyor  94 . Sprockets  147  and  150  are interconnected by chain  152 .  153  is a sprocket mounted on the driver shaft  154  of the film scoring unit  84 . Sprockets  148  &amp;  153  are interconnected by chain  155 . The teeth ratio of sprocket  125  to each of sprockets  126  to  130 ,  134 , and to each of sprockets  136 ,  139 ,  142 ,  143 ,  146 ,  147 ,  148 ,  150  &amp;  153  is 1:1. Teeth ratio of gears  90   a  and  104   a  is also 1:1. The operation of the arrangement of the invention is in the cyclic manner as described below during which valve  21  remains open.  
     [0027] At the beginning of the half cycle of operation of the arrangement , pinion  121  of the Geneva driver  117  is positioned at the mouth of slot  119   a  of the geneva wheel  116  (FIG. 15). During rotation of the geneva driver in the anticlockwise direction pinion  121  travels away from slot  119  a as shown in FIGS. 16 &amp; 17 and no drive is transmitted to the Geneva wheel  116  and the solid cleanser feed conveyor  2 , solid cleanser holder forming unit  31  comprising contrarotatable conveyors  32  &amp;  33 , firm pulling units  100   a ,  100   b ,  100   c  &amp;  100   d , film scoring unit  84  and waste film carrying conveyor  98  remains stationary. Ports a &amp; e and ports b &amp; d of valves  20  of the film lamination units  11   a  &amp;  11   b  are connected. Air flows into the piston side and air flows out into the atmosphere from the cylinder side of the cylinders  12 . Pistons  15  of the cylinders  12  along with the movable laminator plates  23  move down towards the stationary laminator plates  27  of the film lamination units. Both the movable laminator plates  23  and stationary laminator plates  27  are being heated by the electric conductors  30  running therethrough. Both the films  156 ,  157  from top unwind rolls  5  positioned in the top lamination unit  11   a  are hot pressed together and laminated into a single top film along the lamination ridges  29  of the movable laminator plate  23  and stationary laminator plate  27  of the top lamination unit  11   a . Similarly both the films  156 ,  156  from the bottom unwind rolls  6  positioned in the bottom lamination unit  11   b  are hot pressed together and laminated into single bottom film along the lamination ridges  29  of the movable laminator plate  23  and stationary laminator plate  27  of the bottom lamination unit  11   b . The laminated top and bottom films emerging from the lamination units are marked  157 . The films on the unwind rolls may be of the same or different materials, textures or colours as required. Ports b &amp; d and ports a &amp; e of valve  49  of the solid cleanser sealing unit  41  are connected. Air flows into the piston side and air flows out into the atmosphere from the cylinder side of the cylinder  42  of the solid cleanser sealing sealing unit  41 . The piston  45  of cylinder  42  along with the movable die plate  51  moves down towards the stationary die plate  55 . Both the die sockets  57  in the movable die plate  51  and stationary die plate  55  are being heated by the electric conductors  58  running around them. The movable die plate  51  closes on the stationary die plate  55  and holds the solid cleanser holder positioned therebetween within the die sockets  57  and heat seals together the bottom and top films around the solid cleanser at the peripheries of the die sockets. Ports b &amp; d and ports a &amp; e of valve  67  of solid cleanser holder cutting unit are connected. Air flows Into the piston side and air flows out into the atmosphere form the cylinder side of cylinder  60  of the solid cleanser holder cutting unit. The piston  63  of cylinder  60  along with the punch plate  69  closes on the die plate  80  and holds the solid cleanser holder positioned therebetween within the die cavities and cuts the solid cleanser holder at the peripheries of the die cavities. On being cut and separated from the bottom and top films, the solid cleanser holder holds  160  falls down through open bottom of the die cavity  82  in the die plate  80  and corresponding opening  83  in the base  81  of the supporting structure  62 . While the punch plate  60  closes on the die plate  80  and cuts and separates the solid cleanser holder from the films, the retainer flange  78  presses against the films under spring tension and holds the films in position to facilitate cutting of the solid cleanser holders. The retainer flange slides in and out in the punch plate due to its being tensioned by springs  79  and fixed to the screw members  75  which are movable disposed in the holes  73 . The outward movement of the screw members in holes  73  and hence that of the retainer flange is restricted by shoulders  77  as the heads of the screw members abuts the shoulders at the extreme outward position of the screw members. The size of the edges or frills of the solid cleanser holder from the sealing point thereof depends on the larger peripheries of the die cavities as compared to the die sockets. At the end of the half cycle of operation of the arrangement, the position of the pinion  121  of the Geneva driver  117  is as shown in FIG. 17. The pinion  121  is about to enter slot  119   f  of the Geneva wheel  116 . During Further rotation of the Geneva driver in the anticlockwise direction the pinion  121  travels into the slot  119   f  of the geneva wheel (FIG. 18) and travels back from the side slot  119   f  of the Geneva wheel as Shown in FIG. 19. During this half cycle drive is transmitted to the Geneva wheel and it rotates in the clockwise direction. Consequently drive is transmitted to the solid cleanser feed conveyor  2 , solid cleanser holder forming unit  31  comprising contrarotatable conveyors  32  &amp;  33 . Film pulling units  100   a ,  100   b ,  100   c  &amp;  100   d  and film scoring unit  84  and waste film carrying unit  98   u . Solid cleansers  158  being fed from the feed end of the conveyor  2  in the pockets formed by pairs of spaced upright members  4 , are moved forward y the feed conveyor. Due to momentum of movement of the feed conveyor, the solid cleanser at the discharge end of the infeed conveyor is pushed by the advancing upright member  4  at the rear side of the solid cleanser  158  into the laminated bottom film  157  at the feed end  37   a  between the contrarotatable conveyors  32  &amp;  33  over the flat protrusion  40 . The contrarotating rollers of the film pulling units  100   a  &amp;  100   b  pull the laminated bottom and top films from the lamination units  11   a  &amp;  11   b  and keep them taut. In the solid cleanser holder forming unit  31 , the bottom film  157  carrying the solid cleansers and the top film  157  overlying the solid cleansers form holders for the solid cleansers and are moved forward by and between the contrarotating conveyors  32  &amp;  33 . The bottom and top films having solid cleansers interposed there between enter the solid cleanser holder sealing unit  41 . The contrarotating rollers of the film pulling unit  100   c  pull the bottom and top films with the sealed solid cleansers holders emerging from the solid cleanser sealing unit and feed them to the solid cleanser cutting unit  59  one at a time. The contrarotating rollers of the film pulling unit  100   d  pull the bottom and top films from the solid cleanser cutting unit  59  through the film scoring unit  84  in which the rotary disc cutter  91  cuts or scores the waste films into two lengthwise, which remain as webs between adjacent cutouts of solid cleanser holders after they are cut and separated. The waste films emerging from the pulling unit  100   d  are carried onto the waste film carrying conveyor  98 . The waste films are cut and removed from the waste film carrying conveyor as and when required.  
     [0028] Simultaneously ports b&amp; c and ports a &amp; d of valves  20  are connected. Air flows into the cylinder side and air flows out in the atmosphere form the piston side of the cylinders  12  of the film lamination units  11   a  &amp;  11   b . The piston  15  of the cylinders  12  move up into their original position. Ports b&amp; c and ports a &amp; d valve  49  are connected. Air flows into the cylinder side and air flows out into the atmosphere form the piston side of cylinder  42  of the solid cleanser holder sealing unit  41 . The piston  45  of cylinder  42  moves up to its original position. Ports b &amp; c and ports a &amp; d of value  67  are connected. Air flows into the cylinder side and air flows out in the atmosphere from the piston side of cylinder  60  of the solid cleanser holder cutting unit  59 . The piston  63  of the cylinder  60  moves up to its original position. The arrangement is now ready for the next cycle of operation.  
     [0029] Due to the intermittent drive and feeding of solid cleansers into the solid cleaner holder forming unit in a cycle of operation of the arrangement a gap is maintained between two solid cleansers in the solid cleanser holder forming unit. The temperature controllers sense the temperatures of the laminator plates and movable die plate and corresponding stationary die plate through the thermostats and cut of the power supply when the temperature exceed the set limits. The film tensioning rollers keep the films under tension. The bushes are to minimise friction between the guide plates and respective guide rods and render the up and down movement of the guide plates smooth.  
     [0030] The film lamination units, solid cleanser holder forming unit, solid cleanser holder sealing unit, solid cleanser holder cutting unit, film pulling units film scoring unit and solid cleanser pockets may be of different constructions. There may be more than four film pulling units. Instead of pneumatic cylinders, hydraulic cylinders may be used. There may be more than two film unwind top rolls and more than two film unwind bottom rolls and corresponding number of films to be laminated. The waste film carrying conveyor and film scoring unit are optional. Instead of waste film carrying conveyor and film scoring unit are optional Instead of waste film carrying conveyor some other arrangement may be used to carry used films. The sizes and profiles of the die sockets and die cavities will change depending upon the sizes and profiles of the solid cleansers and solid cleanser holders. The arrangement may include a solid cleanser feeding unit. Instead of film unwind rolls the film feeding arrangement may be different Such variations of the invention are to be construed and understood to be within then scope of the invention.