Patent Publication Number: US-2001000286-A1

Title: Magazine for storing leaflets

Description:
FIELD OF THE INVENTION  
       1. The invention relates in general to an apparatus for positioning leaflets on containers or inserting leaflets inside containers in a production environment. The invention finds applications mainly in the pharmaceutical industry where comprehensive information about the product must be included in each container sold in the market. The apparatus is positioned next to a conveyor system on which containers are transported and then adjusted to either affix leaflets to the outer part of the containers or insert leaflets inside the containers. The apparatus allows easy refilling of leaflets and can be rapidly adapted to dispense leaflets of different sizes.  
       BACKGROUND OF THE INVENTION  
       2. Many consumer products, especially pharmaceutical products are required to provide information about the product and/or instructions on the use of the product with each package sold on the market. Square folded leaflets is the most common format for providing that information to the consumer and these may come in a variety of sizes. Leaflets are either inserted into the package or affixed to an outer portion of the package. Many machines have been developed to insert leaflets into containers by means of endless belts with clips which effectively carry and hold the leaflet until it is dumped into the container. Machines designed to affix leaflets to the outer part of a container are not as common and one must look at labeling machines to find devices that produce a similar result. However, labels are usually made of more resilient material than leaflets, are not folded, and one side is often coated with a strong glue. These machines are often complex and require that the container be held firmly when the label is applied to the outer part of the container. Machines designed to both insert leaflets into containers or affix leaflets to the outer part of containers are practically non-existing.  
       3. In all machines of the prior art, the mechanisms for feeding leaflets or labels to the dispensing area are unreliable and cumbersome and problems arise during operation. Leaflets may get misaligned or get caught and the production must be stopped to rearrange the stored leaflets. Leaflets are often stored and fed through a cartridge that features spring loaded elements to push the row of leaflets to the dispensing area. Once the cartridge is emptied, it must be replaced and reloaded and this operation may require that the machine be stopped.  
       4. Considering the wide application, especially in the pharmaceutical industry, of this type of apparatus, there is a demand for an leaflet dispensing apparatus better adapted to position leaflets either on a container or inside a container, that is compact, easy to operate and reliable.  
       OBJECTS AND STATEMENT OF THE INVENTION  
       5. It is thus an object of the invention to provide a leaflet dispensing apparatus specifically adapted to be reloaded with new leaflets in a manner that is quick, simple and reliable.  
       6. It is another object of the invention to provide a leaflet dispensing apparatus that can affix leaflets to a plurality of position on a container and that can insert a leaflet inside a container.  
       7. It is another object of the invention to provide a simple mechanisms for removing leaflets from a stored position and to transport leaflets to the dispensing area.  
       8. It is another object of the invention to provide magazines for packaging leaflets and for use as pre-loaded cartridge for the production environment.  
       9. As embodied and broadly described herein, the invention provides a leaflet dispensing apparatus comprising:  
       10. a main structural body;  
       11. a carousel rotatably mounted to said main structural body, said carousel including a plurality of magazines adapted to hold leaflets, each of said magazine having at least one open extremity through which said leaflets may enter or exit, said magazines being disposed in an upright position wherein said at least one open extremity opens downwardly;  
       12. a retaining plate positioned below said magazines and adapted to close said at least one open extremity, said retaining plate including an orifice in communicative relation with an intermediate chute;  
       13. a dispensing wheel rotatably mounted to said main structural body having an angled peripheral side, said peripheral side including at least one pocket adapted to remove and transport said leaflets, said dispensing wheel in communicative relation with said intermediate chute; and  
       14. a dispensing blade adapted to move a leaflet carried by said dispensing wheel towards a container.  
       15. As embodied and broadly described herein, the invention also provides a leaflet dispensing apparatus adapted to deposit pieces of folded printed matter into or onto small containers in a production line; said apparatus including a support, a main structural body and a revolvable carousel, said carousel being, in operation, adapted to transport a plurality of vertically disposed cartridges; said cartridges being adapted to be filled with said pieces of folded printed matter and to dispense the same by gravity into an intermediate chute; said apparatus further comprising a rotatable dispensing wheel; said dispensing wheel including a plurality of vacuum-actuated pockets about its periphery; each of said pockets being adapted in operation to receive one of said pieces of folded printed matter from said chute; said dispensing wheel being positioned on said apparatus such that each of said pockets is adapted to align one at a time with an exit port of said intermediate chute during rotation of said dispensing wheel; the periphery of said wheel being positioned adjacent a container conveyor and a removal knife such that, in operation, as each of said pockets approaches said conveyor said knife removes said pieces of folded printed matter and deposits it into or onto a container.  
       16. In a preferred embodiment of the invention, the leaflet dispensing apparatus comprises a main structural body on which a carousel, featuring a plurality of magazines each containing a predetermined quantity of leaflets, is mounted. The carousel is in communicative relation with an intermediate chute which enables the transfer of leaflets from a magazine of the carousel to a dispensing wheel located immediately below the intermediate chute. The dispensing wheel is a rotatable disc adapted, in operation, to remove a leaflet from the intermediate chute, to transfer and deliver the leaflet to an oncoming container transported on a conveyor belt. The dispensing wheel features a plurality of pockets each having a small vacuum chamber that creates the necessary suction to remove a leaflet from the intermediate chute and to hold the leaflet during transport to the container traveling on the conveyor belt. To assist in the positioning of the leaflet onto or into the container, a dispensing blade is preferably provided to push the leaflet at the opportune time i.e. when the leaflet is located next to the container. Glue may be applied to the leaflet as the leaflet is being transported by the dispensing wheel or it may be applied to the container itself upstream from the apparatus.  
       17. The carousel ensures a steady flow of properly oriented leaflets to the intermediate chute by storing the leaflets in magazines designed specifically to that effect. The carousel is constructed with a central star-wheel in which a plurality of magazines containing leaflets are placed in the upright position at regular intervals. In operation, one magazine is aligned with the intermediate chute in order to transfer its content of leaflets to the intermediate chute. Once a magazine is empty, the carousel rotates in a step-like manner to position the next full magazine in alignment with the intermediate chute. The intermediate chute acts as a buffer zone or reserve from the moment a magazine is empty to the moment a full magazine is brought in alignment with it. Once all the magazines of a carousel are empty, the entire carousel can be replaced quickly and easily with a new carousel carrying full magazines.  
       18. Other objects and features of the invention will become apparent by reference to the following description and the drawings.  
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     19. A detailed description of the preferred embodiments of the present invention is provided herein below, by way of example only, with reference to the accompanying drawings, in which:  
     20.FIG. 1 is a perspective view illustrating the complete leaflet dispensing apparatus located next to a conveyor system according to the invention;  
     21.FIG. 2 is a perspective view of a container with a leaflet affixed to its side;  
     22.FIG. 3 is an enlarged perspective view of the mechanisms that dispense and positions the leaflets according to the invention;  
     23.FIG. 4 is a perspective view of dispensing wheel according to the invention;  
     24.FIG. 5 is a side elevational view taken at line  5 — 5  of FIG. 1 illustrating the internal parts of the leaflet dispensing apparatus according to the invention;  
     25.FIG. 6 is an enlarged side elevational view illustrating the leaflet dispensing apparatus of FIG. 5 with the carousel being removed when empty;  
     26.FIG. 7 is a top plan view of the leaflet dispensing apparatus according to the invention;  
     27.FIG. 7 a  is a top plan view of the leaflet dispensing apparatus illustrating a second embodiment of the carousel according to the invention;  
     28.FIG. 8 is an exploded view of the leaflet dispensing apparatus according to the invention;  
     29.FIG. 9 is a perspective view of a typical leaflet refilling magazine according to the invention;  
     30.FIG. 9 a  is partial elevational view of the mechanism to secure a typical leaflet refilling magazine according to the invention;  
     31.FIG. 10 is an enlarged side elevational view of the leaflet dispensing apparatus according to the invention prior to affixing a leaflet on a container;  
     32.FIG. 11 is a plan view of the leaflet dispensing apparatus according to the invention taken at line  11 — 11  of FIG. 10;  
     33.FIG. 12 is an enlarged side elevational view of the leaflet dispensing apparatus according to the invention affixing a leaflet on the side of a container;  
     34.FIG. 12 a  is a partial elevational view of the leaflet dispensing apparatus according to the invention shown of FIG. 12;  
     35.FIG. 13 is a plan view of the leaflet dispensing apparatus according to the invention taken at line  13 — 13  of FIG. 12;  
     36.FIG. 14 is an enlarged side elevational view of the leaflet dispensing apparatus according to the invention affixing a leaflet on the top of a container;  
     37.FIG. 14 a  is a perspective view of a container with a leaflet affix on its top.  
     38. In the drawings, preferred embodiments of the invention are illustrated by way of examples. It is to be expressly understood that the description and drawings are only for the purpose of illustration and are an aid for understanding. They are not intended to define the limits of the invention.  
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
     39. With reference to FIG. 1 of the annexed drawings, the present invention provides a novel leaflet dispensing apparatus designated by the reference numeral  20 . The apparatus  20  is constructed of a supporting structure  21  featuring adjustable legs  23  provided to adjust the height of the apparatus, a main structural body  22  and a carousel  30  rotatably mounted to the main structural body  22  in which is stored leaflets  25  to be dispensed. The main structural body  22  is constructed with an angular section  24  to which is mounted a rotatable dispensing wheel  50  adapted to retrieve leaflets  25  from carousel  30  and, to transport and deliver the leaflets  25 , one by one, to a container  26  traveling on a conveyor system  27  and guided and supported by a guide rail  28 .  
     40.FIGS. 3 and 4 focus on the dispensing wheel  50  and its elements and ancillaries. The dispensing wheel  50  is a disc of sufficient thickness to provide support to a leaflet  25 . The periphery  52  of the dispensing wheel  50  is angled and it features a plurality of pockets  54 , each having a smoothly angled entry surface  55  and a sharply angled retaining edge  56 . Inside each pockets  54 , is a small vacuum chamber  57  located on the entry surface  55 . The purpose of chamber  57  is to create a suction of sufficient force to remove a leaflet  25  from an intermediate chute  32  and hold the leaflet  25  as the dispensing wheel  50  rotates and transports the leaflet  25  towards the conveyor system  27 .  
     41. A dispensing blade  60  is provided to cooperate with the dispensing wheel  50  to position leaflets  25  onto containers  26  or inserting leaflets  25  into containers  26 . The dispensing blade  60  is preferably activated with a pneumatic actuator  62  (shown in FIG. 5 and FIG. 6). At the opportune time, the dispensing blade  60  moves towards a container  26  passing on the conveyor  27  and in the process, pushes a leaflet  25  held in a pocket  54  onto the top or the side of container  26  or into container  26 . There are two types of dispensing blades  60  which are of similar design. The first type has an extended upper flange to push the leaflet onto the cap of container  26  or into the container  26  while the second type has an extended lower flange instead, to push the leaflet onto the side of container  26 .  
     42. Now referring to FIGS. 5 and 6, it can be seen that the periphery  52  of the dispensing wheel  50  is angled in such a way as to enable the removal of a leaflet  25  from the substantially vertical intermediate chute  32  and the delivery of that same leaflet  25  onto a container  26 . In a preferred embodiment, the periphery  52  of the dispensing wheel  50  is angled at 45 degrees in relation to the axis of rotation of the dispensing wheel  50 . In this arrangement, the periphery  52  of the dispensing wheel  50  is substantially parallel to the leaflet  25  held in the intermediate chute  32  and it is also substantially parallel to the side portion of container  26  transported by the conveyor  27 .  
     43. Referring to FIG. 6, the dispensing wheel  50  is mounted at its center to the central column  76  of the vacuum rotary connector  70 . A motor  101  linked to the central column  76  through a shaft  56  imparts rotary motion to the central column  76 . The central column  76  is supported at one end by its connection to the motor  101  and at its other end, by a central bearing  75 . The vacuum rotary connector  70  is mounted to the angular section  24  of the main structural body  22 . The axis of the vacuum rotary connector  70  is oriented at an angle consistent with the angle of the periphery  52  of the dispensing wheel  50 . In a preferred embodiment, the vacuum rotary connector  70  is mounted to the angular section  24  at an angle of 45 degrees from the vertical.  
     44. The vacuum rotary connector  70  effectively imparts rotary motion to the dispensing wheel  50  and it also distributes vacuum pressure to the various chambers  57  of the dispensing wheel  50  by connecting a vacuum source to the various chambers  57  through vacuum lines. The vacuum chambers  57  previously described in FIGS. 3 and 4 are connected to vacuum lines  71  drilled into the dispensing wheel  50 . The vacuum lines  71  communicate with the central column  76  through vacuum lines  72  located underneath the dispensing wheel  50 . The central column  76  features vacuum lines  73  drilled through its center. Each vacuum line  73  is itself linked to a vacuum source (not shown) by the ports  74  of the body  77  of the vacuum rotary connector  70 . Each of the vacuum lines  73  is connected with one port  74  via a groove at their mating point so that the vacuum connection is maintained for a predetermined segment of the total rotation of the rotating column  76 . This vacuum connection arrangement enables the vacuum pressure to be turned on or turned off in the various vacuum chambers  57  of the pockets  54  as a function of the geometrical position of the individual pockets  54 .  
     45. Leaflets  25  to be dispensed are stacked up in individual magazines  40  which are held in the upright position in the carousel  30  by a central star-wheel  34 . The carousel  30  is rotatably mounted at the central star-wheel  34  on a central post  38  and secured to the central post  38  with only one large handle screw  35  for easy installation and removal. The central star-wheel  34  and the central post  38  have a positioning mechanisms (not shown) to insure that when the central star-wheel  34  is installed on the central post  38 , it is in the proper radial orientation. The central post  38  is connected to a motor and gearbox  39  (as shown in FIG. 5) which imparts rotary motion to the carousel  30  in a step-like or indexed manner.  
     46.FIG. 7 illustrates a typical carousel viewed from above showing the radial positioning of each magazine  40 . The rotary motion of the central post  38  is indexed into as many segments as there are magazines  40  in the carousel  30 . In the illustrated example, there are sixteen magazines  40 ; therefore the rotation of the central post  38  will be divided into sixteen equal segments of 22.5 degrees each. The number of magazines  40  stored in a carousel is not restricted to the illustrated example and can be any number. The rotary motion of the central post  38  simply has to be indexed in relation to the radial distance between two magazines  40  held in the carousel  30 .  
     47. As a variant of the carousel  30 , FIG. 7 a  illustrates the magazines  40  mounted on a conveyor system  88 . This arrangement permits the loading of more magazines  40  and therefore, more leaflets  25  into the apparatus. Empty magazines  40  may be replaced individually at a point downstream from the dispensing area or the entire conveyor system  88  may be replaced with a new one with full magazines  40 . The conveyor system  88  operates essentially the same way as the carousel  30  wherein each magazine  40  is positioned in alignment with the intermediate chute  32  into which it unloads its leaflets  25 . The displacement of the conveyor system  88  to replace an empty magazine  40  is also indexed in relation to the distance separating two magazines  40  held in the conveyor system  88 .  
     48.FIG. 8 is an exploded view of the main components of the carousel  30  showing at the bottom section of the carousel  30 , a retaining plate  36  comprising an orifice  37  which opens onto the intermediate chute  32  located immediately below the retaining plate  36 . The purpose of the retaining plate  36  is to partially support the magazines  40  and specifically to prevent leaflets  25  from escaping through the open end  48  of the magazines  40 . The retaining plate  36  is oriented with its orifice  37  lined up with the intermediate chute  32  and does not rotate with the carousel  30 . The upper surface of the retaining plate  36  is smooth to allow easy motion as the bottom leaflet  25  of every magazine  40  slides on this upper surface as the carousel  30  rotates.  
     49. Each magazine  40  is mounted to an aperture  42  of the star-wheel  34  with the agency of an adapter  41 . The magazine  40  is positioned into the adapter  41  and held within by the mating of spring loaded dowels  43  with the grooved openings  44  located on each side of the magazines  40 . The adapter  41  is mounted to the aperture  42  of the star-wheel  34  and locked into position by inserting a fastener  45  though the adapter  41  and into a hole  46  located behind each aperture  42 . The adapter  41  is provided so that the star-wheel  34  may accommodate a variety of magazines  40  of different sizes. The size of the magazine  40  essentially depends on the sizes of the leaflets  25 .  
     50. The intermediate chute  32  is mounted to a support plate  33  on which the retaining plate  36  is seated. The intermediate chute  32  comes in a variety of sizes to accommodate leaflets  25  of different sizes; it can removed and replaced by an intermediate chute  32  of different size as need be. The purpose of the intermediate chute  32  is to create a buffer zone or a reserve of leaflets  25  so that when a magazine  40  is empty and the carousel rotates to bring a full magazine in line with the orifice  37  of the retaining plate  36 , there are still leaflets available to the dispensing wheel  50 . This arrangement prevents the flow of containers  26  from being stopped. The intermediate chute  32 , as the magazines  40 , is dimensioned to closely fit a particular size of leaflet  25  to insure that the leaflets are properly guided and do not become misaligned. The intermediate chute  32  features, at its bottom end  90 , edges  92  adapted to hold the sides of a leaflet while leaving the central portion of the leaflet exposed to the dispensing wheel  50 . As can be seen in FIG. 8, the periphery  52  of the dispensing wheel  50  is located directly between the edges  92  of the intermediate chute  32 . The dispensing wheel  50  is therefore able to remove the exposed leaflet  25  when a pocket  54  passes by the intermediate chute  32  with the suction created by the vacuum chamber  57 .  
     51. In operation, one magazine  40  of the carousel  30  is lined up with the orifice  37  leading to the intermediate chute  32 . Leaflets  25  travel down by gravity into the intermediate chute  32 . Once a magazine  40  has unloaded all its leaflets  25 , the carousel  30  is rotated so as to bring into alignment with the orifice  37 , the next full magazine  40 . Once all the magazines  40  of the carousel  30  are empty, the empty carousel  30  is removed by simply undoing the large screw handle  35  (as shown in FIG. 6). A new carousel  30  with full magazines  40  is then installed and the screw handle  35  re-fastened.  
     52. Referring to FIGS. 9 and 9 a,  the magazines  40  are receptacles or cases adapted to hold leaflets to be dispensed. Magazines  40  Magazines  40  are tailor-made to fit different size of leaflets  25 . The interior of the magazines  40  is dimensioned to closely fit a particular size of leaflet  25  so that the leaflets  25  are unable to rotate or become misaligned and therefore remain in the ideal orientation for dispensing. The magazines  40  are long, thin rectangular receptacles with one extremity  48  opened and have narrow grooved openings  44  on two opposite sides of the magazine  40  which are provided to secure the magazine  40  in a certain position into the adapter  41 . The magazines  40  also features a long narrow aperture  47  extending substantially the length of the magazine  40  through which the amount of leaflets left in the magazine  40  can be verified. Leaflets  25  are inserted in the magazine  40  through the open extremity  48  and oriented so that when the magazine  40  stands upright, the leaflets  25  are stacked up. The magazine  40  is positioned into the adapter  41  and held within the adapter  41  by the mating of spring loaded dowels  43  with the grooved openings  44  located on each side of the magazines  40  as shown in FIG. 9 a.  It can be seen that a small gap exist between the lower spring loaded dowels  43  and the bottom of the narrow grooved openings  44  which permits some minor movements of the magazine  40 . The magazines  40  are installed in the carousel  30  with the open extremity  48  facing down. In operation, the stacked leaflets  25  are discharged through the open extremity  48  into orifice  37  of the retaining plate  36  and into the intermediate chute  32 . Magazines  40  can be produced out of inexpensive molded material which can be simply discarded after use. Magazines  40  can also be produced out of a more rigid molded material permitting the recycling of magazines  40  by returning them to the leaflets manufacturer for reloading. Magazines  40  can also be of a more permanent type for the purpose of on-site reloading. The magazine  40  is removed from carousel  30 , refilled with new leaflets and reinstalled in the carousel  30 .  
     53. FIGS.  10  to  13  illustrate the dispensing wheel  50  and dispensing blade  60  in operation from two points of view and at two different moments. In FIGS. 10 and 11, the dispensing wheel  50  is shown in a counterclockwise rotation, the dispensing blade  60  is retracted, a pocket  54  of the dispensing wheel  50  is about to pick up a leaflet  25  from the intermediate chute  32 , a second pocket  54  is carrying a leaflet  25  towards the containers  26 , a third pocket  54  is about to release a leaflet  25  onto a container  26  and a fourth pocket  54  is empty after having released a leaflet  25 . FIGS. 12 and 13 illustrate the leaflet dispensing apparatus  20  one instant later. In FIG. 13, the pocket  54  located at the 12 o&#39;clock position pulls a leaflet  25  from the intermediate chute  32  with the suction force created by the vacuum chambers  57  inside the pocket  54 . At the 9 o&#39;clock position, a glue dispensing device may be installed (not shown) to apply a thin layer of glue to the leaflet  25  held and carried by the dispensing wheel  50  as it passes by that position. At the 6 o&#39;clock position, the vacuum rotary connector  70  shuts the vacuum pressure of that particular pocket  54  at the same moment the dispensing blade  60  extends and pushes the leaflet  25  onto the passing container  26 . During the leaflet dispensing sequence, the container  26  is held in place, from the opposite end, by the guide rail  28  which prevents the container  26  from falling off the conveyor belt  27 . The dispensing blade  60  applies a small pressure to the leaflet  25  to ensure that the glue applied previously on the leaflet  25  adheres firmly to the container  26 .  
     54.FIG. 14 illustrates the variant in which the leaflet  25  is positioned and affixed to the top portion of the container  26 . It can be seen that the dispensing blade  60  used for this purpose has a longer upper flange than the model used for positioning leaflets  25  to the side of the containers  26 . Either type of dispensing blade  60  may be used when leaflets  25  are to be inserted into the container  26 . When inserting leaflets  25 , the containers  26  are transported on the conveyor belt  27  without their lids so that when a leaflet  25  is pushed by the dispensing blade  60 , the leaflet  25  falls into the container  26 .  
     55. The above description of preferred embodiments should not be interpreted in a limiting manner since other variations, modifications and refinements are possible within the spirit and scope of the present invention. The scope of the invention is defined in the appended claims and their equivalents.