Abstract:
An apparatus for separating flexible packages has a first stage. The first stage has an inclined conveyor having a lower end for receiving flexible packages and an upper end. The inclined conveyor has an inclination sufficient for causing an overlying flexible package to slide relatively to an underlying flexible package as the flexible packages travel from the lower end to the upper end. A drum is rotatably mounted for receiving the flexible packages from the upper end. The drum has a plurality of radially extending resilient paddles for successively engaging and carrying the flexible packages as the drum rotates. The successive engagements and rotation vibratingly separate the flexible packages and discharges a stream of substantially separated flexible packages.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a package handling device for separating and orienting flexible pouched articles. In particular, the present invention provides an apparatus for mechanically separating and orientating pouched articles for individually inserting each pouched article into a container such as a bag or box. 
     BACKGROUND OF THE INVENTION 
     Many products are packaged in flexible pouches or sealed bags or envelopes. Typically, these pouches are of a rectangular shape and contain food products such as seasonings, salad dressings, cereals, and candies. For example, a caesar salad kit includes a foil pouch of salad dressing, a cellophane pouch of croutons, a foil envelope of seasonings, all packaged in a cellophane bag of chopped romaine lettuce. However, each of these items must be hand sorted and manually placed within the cellophane bag for sealing. The reliance on manual labour increases food packaging time and costs. 
     There does not exist an automated machine which can separate and orient pouched product for insertion into a recipient container. The flexibility of the pouch prevents effective sorting and handling. As a pouch is handled, it changes shape and clumps together making it difficult to separate the pouched products and then orient them so that each can be inserted into a recipient container one at a time. 
     There are prior art devices which separate and orient hard-surfaced objects such as wooden flat holder sticks or nuts and bolts. For example, U.S. Pat. No. 4,729,501, Lowrance, provides an automatic feeder apparatus for automatically inserting flat holder sticks into individual food products such as ice cream bars and wieners. This device uses a series of agitator rollers having a plurality of circumferentially spaced longitudinal-shaped flutes which agitates the unaligned sticks and discharges the sticks onto a set of ramps to slide into a slot. This device would not be suitable for flexible items since the flexible items would tend to clump together and be delivered in bunches of two or more. 
     SUMMARY OF THE INVENTION 
     The disadvantages of the prior art may be overcome by providing a novel apparatus for the separation and orientation of pouched articles. 
     According to one aspect of the invention, there is provided an apparatus for separating flexible packages having a first stage which has an inclined conveyor having a lower end for receiving flexible packages and an upper end. The inclined conveyor has an inclination sufficient for causing an overlying flexible package to slide relatively to an underlying flexible package as the flexible packages travel from the lower end to the upper end. A drum is rotatably mounted for receiving the flexible packages from the upper end. The drum has a plurality of radially extending resilient paddles for successively engaging and carrying the flexible packages as the drum rotates. The successive engagements and rotation vibratingly separate the flexible packages and discharges a stream of substantially separated flexible packages. 
     According to another aspect of the invention, there is provided an apparatus for separating flexible packages having a plurality of stages operably connected together to serially process the flexible packages. Each stage has an inclined conveyor having a lower end for receiving flexible packages and an upper end. The inclined conveyor has an inclination sufficient for causing an overlying flexible package to slide relatively to an underlying flexible package as the flexible packages travel from the lower end to the upper end. A drum is rotatably mounted for receiving the flexible packages from the upper end. The drum has a plurality of radially extending resilient paddles for successively engaging and carrying the flexible packages as the drum rotates. The successive engagements and rotation vibratingly separate the flexible packages and discharges a stream of substantially separated flexible packages. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Drawings which illustrate embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein: 
     FIG. 1 is a side elevational view of an apparatus for separating and orienting pouched products in accordance with the present invention; 
     FIG. 2 is an end elevational view of a first stage of the apparatus of FIG. 1; 
     FIG. 3 is a side elevational view of the apparatus of FIG. 1, illustrating the sensors for controlling the efficient throughput of the apparatus; and 
     FIG. 4 is an end elevational view of a second embodiment of the first stage of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIG. 1, the present invention is generally illustrated. The apparatus of the present invention generally comprises a metal frame  6  for supporting the parts of the apparatus. The apparatus generally comprises a first stage S 1 , a second stage S 2 , a third stage S 3  and an injector I 1 . The stages are operably connected together for serial processing of the stream of flexible pouches. The stages define a path of a stream of pouches flowing from an upstream end to a downstream end at injector I 1 . 
     Referring to FIG. 2, the first stage S 1  is illustrated. The first stage S 1  comprises a hopper  8  is mounted on frame  6  having an open bottom  14  for gravity feeding of the pouches  12  onto conveyor  16 . 
     Pouches  12  are preferably flexible pouched products which have an outer membrane for containing the contents thereof. The products are normally relatively thin, having a length greater than a width greater than a thickness. It is understood that pouches  12  could be any configuration and could range in flexibility. 
     Conveyor  16  transports the pouches on the conveyor belt  18 . Conveyor belt  18  has a plurality of transverse ridges  20  to frictionally engage the surface of the pouches  12 . Inclined conveyor  16  transports pouches  12  towards a pair of spaced counter rotating drums  22 . 
     The conveyor surface  18  has a coefficient of friction greater than the coefficient of friction of the surfaces of the pouches  12  themselves. This difference in frictional coefficients facilitates the force of gravity to cause stacked or overlapping pouches  12  to slide downwardly relative to one another staggering the pouches  12 . 
     Each drum  22  is an elongated with a series radially extending flexible paddles  24  running along the length of each drum  22 . The paddles  24  are fabricated from a resilient material, such as rubber or a coated closed cell foam material, to permit paddles  24  to deform as pouches  12  are fed between the counter-rotating drums  22 . It is further contemplated that the paddles  24  may be a series of cylindrical teeth and manufactured from rubber or polyurethane foam. It is contemplated that the size, shape, and flexibility of the paddles  24  and the spacing of the drums  22  may be adjusted to accommodate different types and sizes of flexible packages. 
     Mounted immediately below drums  22  for receiving pouches which have passed therebetween is orienting guides  26  and conveyer  34 . Guides  26  comprises a pair of walls  30  which define a channel  28 . The separation of the wall surfaces  30  is generally equal to the width of the pouches  12 . Guides  26  orient pouches  12  as each falls from between drums  22  to conveyor  34 . 
     Discharge conveyor  34  is positioned below drums  22  and receives the pouched products  12  from drums  22 . Discharge conveyor  34  rotates in the direction of the arrow to feed pouches  12 , which are oriented in a longitudinal direction to the second stage S 2 . 
     Stage S 2  comprises an inclined conveyor  36 , which is similar in construction to the inclined conveyor  16 . The inclined conveyor  36  operates in a manner similar to inclined conveyor  16  to separate bunched or overlying pouches  12  which were missed by the first stage S 1 . 
     Inclined conveyor  36  transports the pouches  12  towards rotating drum  38 . Drum  38  has a number of radially extending paddles  39  which are similar in construction to the paddles  24  of counter-rotating drums  22 . Drum  38  is positioned to receive pouch  12  from conveyor  36 . 
     To improve the separation of the pouches  12 , drum  38  can rotate to have a tip speed of each of the paddles greater than the surface speed of inclined conveyor  36 . Similarly, inclined conveyor  36  can operate at a faster rate than the discharge conveyor  34 . The increase speed in the next downstream components tends to pull each pouch into the next component enhancing the separation of the pouches. 
     A second guide  40  is radially spaced from and extends circumferentially about drum  38 . The guide  40  extend over a flat conveyor belt  46 . The spacing between the guide  40  and the drum  38  and between guide  40  and conveyor belt  46  is approximately equal to the thickness of the pouch  12 . 
     Flat conveyor belt  46  is configured with a substantially triangular travel path. Flat conveyor  46  has a first section  47  for receiving the oriented pouch  12  from drum  38  and guide  40  and a second section  49  spaced from egg belt  44 . First section  47  transports the pouch  12  from the drum  38  to the egg belt  44 . Second section  49  cooperates with egg belt  44  to urge each pouch  12  against the second section  49  during transport thereof. 
     Egg-type conveyor  44  is positioned with respect to second section  49  of conveyor  46  to define a vertical path extending therebetween. Egg-type conveyor  44  has a plurality of flexible semi-circular ridges  45 . The egg belt surface is common to the poultry and egg processing industry. The ridges  45  conform to the shape of the pouch  12  as it is pinched or sandwiched between the conveyor  46  and the egg-type conveyor  44 , thereby holding the oriented pouches  12  in a fixed orientation from the guide  40 . The flexible nature of the ridges  45  on the egg conveyor  44  holds the pouch  12  without damaging it and prevents pouch  12  from losing its longitudinal orientation as it is transported downwardly. 
     A first guide chute  48  is positioned below egg conveyor  44  and conveyor  46  for receiving the pouches  12 . The inner surface  50  of first guide chute  48  has a frusto-conical surface which prevents the longitudinally oriented pouches  12  from rotating and losing orientation during the slide down the chute  48 . 
     Conveyor  52  is positioned at the discharge end of chute  48  to receive each pouch  12 . Conveyor  52  communicates with the third stage S 3  to deliver oriented and separated pouches  12 . 
     Third stage S 3  is a duplicate of second stage S 2 . Third stage S 3  has an inclined conveyor  54 , a rotating drum  56 , paddles  57 , a guide  60 , a belt conveyor  64 , an egg belt conveyor  66 , a chute  68  and a conveyor  72 . Each component of third sage S 3  is identical to the respective components of second stage S 2 . 
     The third stage S 3  is positioned to communicate with second stage S 2 . Inclined conveyor  54  receives each pouch  12  from conveyor  52 . 
     The third stage S 3  communicates with the injector  11 . I 1  comprises an flat conveyer  76  and an egg conveyor  78 . Egg conveyor  78  overlies flat conveyor  76  to define a path therebetween. Preferably, the speed of conveyor flat conveyor  76  and egg conveyor  78  is faster than horizontal belt  72 . If the relative speed of conveyors  76  and  78  is about 25%greater than that of conveyor  72 , then as a pouch  12  is transported from horizontal belt  72  to conveyors  76  and  78 , conveyors  76  and  78  will grab and pull each successive pouch ensuring separation of pouches and thereby reduce the chance of two pouches  12  being deposited into the package  80 . 
     It can now readily be understood by those skilled in the art that the quantum of increased relative speed of the downstream conveyor will depend upon the size and nature of the pouches or products being sorted and separated. It is possible for speeds of the downstream conveyor to be in the order of up to 3 or 4 times faster than the upstream conveyor. 
     In the embodiment illustrated in FIG. 1 and 2, the apparatus of the present invention has a circuitous path serpentining across and about the frame. It can be readily understood by those skilled in the art that the path of the pouches could be arranged in any desired path to deliver the pouches to their final destination for processing. 
     Additionally, a microprocessor coupled with a sensor would cause flat conveyor  76  and egg type conveyor  78  to selectively rotate to eject a longitudinally oriented pouch into an appropriate recipient package  80  one at a time. 
     Each of the conveyors and drums are operatively connected to a number of motors for driving same. Such connections may be any suitable drive engagement known in the art, including chain drives, belt drives or screw drives. 
     In operation of the first stage S 1 , pouches  12  are dumped into hopper  8 . The bottommost pouches will gravity feed through aperture  14  and contact the conveyor surface  18  of the inclined conveyor  16 . The pouches in contact with the conveyor surface  18  will be pulled from the pile in a random manner, sometimes in clumps of pouches. The inclination of the conveyor  16  allows gravity to act upon the pouches  12  to cause the overlying pouches to slide relative to the pouches on the conveyor  16  leaving the leading edge of the pouch on the conveyor available for grabbing by the next component, thereby effecting an initial staggering or separation of the pouches. 
     The counter-rotating drums  22  will engage the leading edge of the pouch. The plurality of radially extending paddles  24  will successively engage and carry the pouches as the drum rotates. The successive engagements and rotation will vibratingly separate the pouches and discharge a stream of substantially separated pouches  12 . The rotation of the drum moves the pouch  12  over top of the receiving drum and then downwardly between the two drums  22 . The speed of rotation of the counter-rotating drums is faster than the speed of the conveyor  18 . The receiving drum  23  will pull the pouch  12  off of the conveyor  18  to separate the pouch from any overlying pouch. The receiving drum  23  will engage the next successive pouch on conveyor  18 . 
     Each pouch  12  is agitated or jostled by the rotating paddles  24  as the pouch  12  is driven between the rotating drums  22  between guides  26 . The jostling and agitating action caused by the rotating paddles  24  urges each pouch  12  to orient in a direction substantially parallel to the wall surfaces  30  of the guides  26 , thereby longitudinally orienting each pouch  12 . Each pouch  12  is deposited on conveyor  34  substantially separated and oriented. 
     In some cases, the pouches  12  may be adequately separated and oriented by the first stage S 1 . However for other types of pouches, additional separation and orientating stages may be necessary to separate and orient the pouches. 
     Referring back to FIG. 1, the pouch  12  is transported along conveyor  34  to the second stage S 2 . Inclined conveyor  36  receives pouches  12  and will urge overlying pouches, if any, to slide relative to the pouch in contact with the conveyor  36 . Drum  38  will grab the leading edge of each pouch  12 . Similar to the first stage, drum  38  is rotating at a tip speed greater than that of the conveyor  36 . The pouch  12  will travel about drum  38  between the paddles  39  and guide  40  and then to conveyor  46 . Conveyor  46  will then transport the pouch  12  downwardly to chute  48  and then to conveyor  52 . 
     The pouch  12  is transported along conveyor  52  to the second stage S 3 . Inclined conveyor  54  receives pouches  12  and will urge overlying pouches, if any, to slide relative to the pouch in contact with the conveyor  54 . Drum  56  will grab the leading edge of each pouch  12 . Similar to drums  22  and  38 , drum  56  is rotating at a speed greater than that of the conveyor  54 . The pouch  12  will travel about drum  56  between the paddles  57  and guide  60  and then to conveyor  64 . Conveyor  64  will then transport the pouch  12  downwardly to chute  68  and then to conveyor  72 . 
     The pouch  12  is then transported to the injector I 1 . Conveyors  76  and  78  will grab each successive pouch  12  from conveyor  72  and will eject the now oriented and separated pouch  12  into package  80 . 
     In the preferred embodiment of the first stage S 1 , two counter-rotating drums  22  have been illustrated. However, as is now apparent to those skilled in the art, one of the drums  22  can be replaced by a guide as described in stages S 2  and S 3 . 
     Referring to FIG. 3, a series of sensors  86 ,  88 ,  90 ,  92 ,  94 ,  96 ,  98 ,  100 , and  102 , are positioned throughout the apparatus to detect the location of pouches  12  at different locations along the path. Preferably, the sensors include a signal generator to emit a signal, such as a laser beam, which is reflected off the pouch  12  as is passes through the field of view or breaks the light beam and a photo electric eye which detects the presence or absence of the laser beam and generates a corresponding detection signal. In each case, the detection signal is sent to a control computer processor which initiates a responsive action as described below. 
     Sensor  86  emits a detection beam  87  immediately below counter-rotating wheels  22 . Sensor  88  emits detection beam  89  to detect the presence of a pouch  12  at the top of inclined conveyor  36 . Sensor  90  emits detection beam  91  near the bottom of the vertical transport path of conveyor  46  and egg conveyor  44 . Sensor  92  emits detection beam  93  to detect a pouch  12  at the bottom of guide chute  48 . Sensor  94  emits detection beam  95  to detect the presence of a pouch  12  at the top of inclined conveyor  54 . Sensor  96  emits detection beam  97  to detect the presence of a pouch  12  near the bottom of egg conveyor  66  and conveyor  64 . Sensor  98  emits detection beam  99  to detect the presence of a pouch falling from conveyors  66  and  64  onto guide chute  68 . Sensor  100  emits a detector beam  101  to detect the presence of a pouch  12  at the end of discharge conveyor  72  at a point adjacent to conveyors  78  and  76 . Sensor  102  emits detection beam  103  to detect the presence of a pouched product  12  near the end of the dispensing means  74 . 
     In operation, the sensors are coordinated to control various conveyors and rotating drums as follows. If a pouch  12  is detected by sensor  102  at the injector I 1 , belts  76  and  78  are signalled to stop. This is the first step in staging pouched product  12  so that it is ready to be inserted into a container  80 . Next, sensor  100  detects whether a pouch  12  is at the downstream end of the discharge conveyor  72 . If not, conveyor  72  is engaged after sensor  98  detects a pouch  12  sliding down chute  68 . If sensor  96  detects a pouch  12  then conveyors  64  and  66  can be disengaged retaining a pouch ready for delivery to chute  68 . If a pouch  12  is detected by sensor  94 , then inclined conveyor  94  can be disengaged. If not, conveyor  94  is engaged after sensor  92  detects a pouch  12  at the bottom of chute  48  and operates until sensor  94  detects a pouch. If sensor  90  then detects a pouch  12  in the downstream end of the opposed counter-rotating conveyors  44  and  46 , then the conveyors  44  and  46  are disengaged. If sensor  88  detects the presence of a pouched  12  at the top of the inclined conveyor  36 , then inclined conveyor  36  is disengaged as product is ready to be delivered to rotating wheel  38 . If sensor  86  detects the presence of a pouch  12  falling below rotating wheels  22 , then rotating wheels  22  and the first inclined conveyor  16  can be disengaged. 
     It is contemplated that sensors helps to ensure a smooth throughput of oriented pouches in a “just in time” delivery system. 
     Referring now to FIG. 4, a second embodiment of the first stage discharge conveyor is illustrated. The discharge conveyor comprises conveyors  134  and  135  arranged in a V shape. Guides  126  are spaced relatively above the conveyors  134  and  135  for orienting pouches as each falls from between drums  22 . Guides  126  has a bar  136  at the downstream end. 
     In operation, pouches will fall between the guides  126  and will be oriented in a direction of the conveyors  134  and  136 . The V orientation of the conveyors  134  and  136  will maintain the general orientation of pouches and will transport each pouch to the next stage. If a pouch stands on end in the general orientation, then bar  136  will tip the pouch over to put the pouch is a desired orientation. It is now understood that the height of the bar  136  will depend on the size of the pouches being processed. 
     It now can be appreciated that the apparatus of the present invention provides an automated device for the separation and orientation of pouched products, thereby reducing the manual labour in the pouch handling process. 
     The above described embodiments of the present invention are intended to be examples of the invention and alterations and modifications may be effected thereto, by those of skill in the art, without departing from the scope of the invention which is defined solely by the claims appended hereto.