Patent Description:
The present invention generally relates to systems and methods for conveying articles in a packaging machine. More specifically, the present invention is directed to a method and a system for combining multiple feeds of the articles prior to loading the articles into cartons.

A method for conveying articles as per the preamble of claim <NUM> and a corresponding system according to the preamble of claim <NUM> are already known from <CIT>. The method and system known from this prior art reference, however, still leave room for improvement.

According to one aspect, the invention provides a method of conveying articles comprises moving a first plurality of articles in a first input lane in a downstream direction to a lane combiner, moving a second plurality of articles in a second input lane in the downstream direction to the lane combiner, and operating the lane combiner to combine the first plurality of articles and the second plurality of articles into a combined plurality of articles in an output lane. The operating the lane combiner comprises engaging a first article from the first plurality of articles with a first combiner wheel, engaging a second article from the second plurality of articles with a second combiner wheel that is out of phase with the first combiner wheel, rotating the first combiner wheel to move the first article into the output lane, rotating the second combiner wheel to move the second article into the output lane after the first article, and the combined plurality of articles comprises the first article and the second article in sequence, wherein the first article is in an inverted orientation relative to the second article.

According to another aspect, the invention provides a system for conveying articles comprises a first input lane and a first plurality of articles (CD) in the first input lane, the first input lane conveying the first plurality of articles, a second input lane and a second plurality of articles (CU) in the second input lane, the second input lane conveying the second plurality of articles, the first plurality of articles are in an inverted orientation relative to the second plurality of articles, and a lane combiner positioned downstream from the first input lane and the second input lane and comprising a first combiner wheel that is out of phase with a second combiner wheel. The first combiner wheel is positioned to engage a first article from a first plurality of articles in the first input lane and the second combiner wheel is positioned to engage a second article from a second plurality of articles in the second input lane, the first article in an inverted orientation relative to the second article. Upon out of phase rotation of the first combiner wheel and the second combiner wheel, the first article is moved into an output lane and the second article is moved into the output lane after the first article to form a combined plurality of articles that comprises the first article and second article in sequence.

Additional embodiments and advantages of the present invention will become apparent from the following description and accompanying figures.

Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.

Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the invention.

The present invention relates to a system and method of conveying or feeding articles prior to loading the articles into cartons in a packaging machine. The system according to the present invention can accommodate articles of any shape. The articles can be containers, bottles, cans, etc. The articles can be used for packaging food and beverage products, for example. The articles can be made from materials suitable in composition for packaging the particular food or beverage item, and the materials include, but are not limited to, aluminum and/or other metals; glass; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; and the like, or any combination thereof.

<FIG> generally illustrates an example embodiment of a system and method <NUM> for conveying/arranging articles or containers C (<FIG>), for example, for being loaded into cartons in accordance with the disclosure. In one embodiment, the system <NUM> can be included in a continuous packaging machine for packaging the articles C for storage, shipping, sale, etc. For example, the packaging machine can continuously or substantially continuously feed articles C to the system <NUM>, which conveys the articles C as described below, which can then be transferred, for example, to a carton or container to form a package.

In the illustrated embodiment, the articles C (e.g., as shown in <FIG>) can be in the form of tubs, cups, pods, etc. having tapered sides S so that the articles C are narrower at their bottoms B than at their tops T. In this regard, the tops T of the respective articles C define a first diameter that is larger than a second diameter defined by the respective bottoms B of the respective articles C.

The top T of each article C can have a rim R and a lid L (e.g., a foil, film, covering, or other suitable lid) that can seal the top T at the rim R. In one exemplary embodiment, the articles C can be for containing a product for brewing a beverage (e.g., coffee, tea, cocoa, etc.) from granulized solids in a single-cup brewing system (e.g., K-Cup pods for single-cup brewing systems available from Keurig Dr. Pepper of Burlington, MA, or other suitable containers and systems).

The system <NUM> includes a lane combiner <NUM>, receives the articles C from two inputs (not shown) at an upstream end <NUM> of the system <NUM>, and conveys the articles C to the downstream end <NUM> of the system <NUM> in a machine direction M. In one embodiment, the articles C fed from the first input can be a first plurality of articles each designated CD and having a foil down orientation (e.g., with the lid L facing downwardly) in a first input lane <NUM> and the articles fed from the second input can be a second plurality of articles each designated CU and having a foil up orientation (e.g., with the lid L facing upwardly) in a second input lane <NUM>. The articles CD and the articles CU have inverted orientations relative to one another.

The lane combiner <NUM> is used to move the articles CD, CU from the respective input lanes <NUM>, <NUM> into a output lane <NUM> so that the articles CD from the first input lane <NUM> alternate with the articles CU from the second input lane <NUM> and so that the articles CD, CU alternate between the foil down and foil up orientations in the output lane <NUM> in a combined plurality of articles <NUM>. In one embodiment, a first sequential article in the output lane <NUM> in the machine direction M is one of an article CU or CD, and every other following article (e.g., a third sequential article, a fifth sequential article, etc.) is an article of the same configuration. In an exemplary embodiment, the articles CD, CU can move in the output lane <NUM> to another portion of a packaging machine to be loaded into cartons. As described herein, the input lanes <NUM>, <NUM> are each in communication with and positioned upstream relative to a combination area <NUM> that is in communication with and positioned upstream from the output lane <NUM>.

As shown in <FIG>, the first input lane <NUM> can include a first outer lane guide <NUM> and a first inner lane guide <NUM>, and the second input lane <NUM> can include a second outer lane guide <NUM> and a second inner lane guide <NUM>. In the illustrated embodiment, the input lanes <NUM>, <NUM> are initially spaced apart at the upstream end <NUM> of the system <NUM> and portions of the input lanes <NUM>, <NUM> are angled toward one another upstream from the lane combiner <NUM> so that the outer lane guides <NUM>, <NUM> are angled inwardly and such that the inner lane guides <NUM>, <NUM> converge at a divider <NUM>. In an exemplary embodiment, the divider <NUM> can extend from and/or be integral with one of the inner lane guides <NUM>, <NUM>.

In one embodiment, the articles CD, CU can move in the input lanes <NUM>, <NUM> on respective input conveyors (e.g., conveyor belts or any other suitable conveyor) to the lane combiner <NUM>. In the illustrated embodiment, as the input lanes <NUM>, <NUM> converge toward the divider <NUM>, the lane guides <NUM>, <NUM> and <NUM>, <NUM> can guide the respective articles CD, CU onto a main conveyor <NUM>, which can move the articles from the respective input lanes <NUM>, <NUM>, through the combination area <NUM>, and into the output lane <NUM>. In one example, the input conveyors can be marginal portions of the main conveyer <NUM> or can be otherwise disposed on either side of the main conveyor <NUM> extending near the upstream end <NUM>. In one embodiment, and with additional reference to <FIG>, the main conveyor <NUM> can include a belt <NUM> or other suitable conveyor driven by a motor <NUM> via wheels or gears <NUM> and can be supported on supports <NUM> (e.g., the belt <NUM> can slide along supports <NUM> as it moves in the machine direction M), as shown best in <FIG>.

Still referring to <FIG>, the articles CD, CU are moved in the machine direction M in the respective lanes <NUM>, <NUM> on the main conveyor <NUM> with the divider <NUM> extending between the lanes.

The lane combiner <NUM> includes a first star wheel or first combiner wheel <NUM> (e.g., that engages the foil down articles CD from the first input lane <NUM>) and a second star wheel or second combiner wheel <NUM> (e.g., that engages the foil up articles CU from the second input lane <NUM>) that are positioned in the combination area <NUM>. The combiner wheels <NUM>, <NUM> are positioned on opposite sides of the lane combiner <NUM> along a lateral axis L1 (e.g., that extends transversely across the width of the main conveyor <NUM>, generally perpendicular to the machine direction M). Each of the combiner wheels <NUM>, <NUM> has a plurality of peaks <NUM> and a plurality of recesses <NUM> interposed with the peaks <NUM>. In one embodiment, the recesses <NUM> can be curved to complement the curved sides S of the articles C and the peaks <NUM> of each combiner wheel <NUM>, <NUM> can be spaced from the respectively adjacent peaks <NUM> so that the recesses <NUM> are sized to receive and engage a respective article CD, CU (e.g., so that the recess <NUM> contour or otherwise extends partially around the side S of the article).

As shown in <FIG>, the combiner wheels <NUM>, <NUM> each have six peaks <NUM> and six recesses <NUM>. Alternatively, the combiner wheels <NUM>, <NUM> could have any suitable number of peaks <NUM> and recesses <NUM>. While the combiner wheels <NUM>, <NUM> are illustrated having a generally symmetrical arrangement, one or more of the combiner wheels <NUM>, <NUM> could include an asymmetrical portion(s).

In the illustrated embodiment, the combiner wheels <NUM>, <NUM> rotate on respective generally parallel axes <NUM> (broadly, respective "first rotational axis" and "second rotational axis") and extend into the downstream ends of the input lanes <NUM>, <NUM> through the respective outer lane guides <NUM>, <NUM> (e.g., through respective slots <NUM> in the outer lane guides <NUM>, <NUM> as shown in <FIG>). In one embodiment, the combiner wheels <NUM>, <NUM> can be mounted on a respective axel or shaft that defines the respective axis <NUM>, and are rotated by a motor <NUM> (<FIG>) via gears or other actuating structure so that the first combiner wheel <NUM> rotates in a counterclockwise direction as viewed from above and the second combiner wheel <NUM> rotates in a clockwise direction as viewed from above as shown in <FIG>. Accordingly, the peaks <NUM> and the recesses <NUM> of the combiner wheels <NUM>, <NUM> each move in the machine direction M at portions thereof disposed in the respective input lanes <NUM>, <NUM>.

As shown in <FIG>, the combiner wheels <NUM>, <NUM> are out of phase with respect to one another. For example, one of the peaks <NUM> of the second combiner wheel <NUM> can move through the second input lane <NUM> at approximately the same time that the midpoint of one of the recesses <NUM> of the first combiner wheel <NUM> moves through the first input lane <NUM>. In this regard, at a selected moment in time, the first combiner wheel <NUM> can be positioned at a first rotational orientation RP1 about the respective axis <NUM> in which a first recess <NUM> of the first combiner wheel <NUM> is positioned in the combination area <NUM> and is offset from a second recess <NUM> of the second combiner wheel <NUM> that is positioned in the combination area <NUM> when the second combiner wheel <NUM> is positioned at a second rotational orientation RP2 about the respective axis <NUM> that is different from the first rotational orientation RP1. In one embodiment, when the first recess <NUM> of the first combiner wheel <NUM> is positioned in the combination area <NUM>, a peak <NUM> of the second combiner wheel <NUM> extends at least partially across the second input lane <NUM>. Similarly, in one embodiment, when the first recess <NUM> of the second combiner wheel <NUM> is positioned in the combination area <NUM>, a peak <NUM> of the first combiner wheel <NUM> extends at least partially across the first input lane <NUM>.

Accordingly, in one embodiment, the first combiner wheel <NUM> is arranged for receiving a foil down article CD (broadly, "first article") from the first input lane <NUM> in the first recess <NUM> and moving the first article CD into the output lane <NUM>, which can be sequentially followed by a foil up article CU (broadly, "second article") from the second input lane <NUM> that can be received and engaged by the second combiner wheel <NUM> and moved into the output lane <NUM> after the first article CD.

In the illustrated embodiment, the output lane <NUM> can include respective first and second lane guides <NUM>, <NUM> that can at least partially define a combination area <NUM> therebetween that includes a funnel portion <NUM> at an upstream end of the output lane <NUM> that can converge in the machine direction M to accommodate the width of the articles CD, CU in the output lane <NUM>. The funnel portion <NUM> includes a respective first sloped surface and a second sloped surface defined by the respective lane guides <NUM>, <NUM> and that are arranged to converge toward one another. As shown in <FIG>, the upstream ends of the lane guides <NUM>, <NUM> are positioned to be proximate the downstream ends of the respective outer lane guides <NUM>, <NUM> of the input lanes <NUM>, <NUM>. In one embodiment, the downstream ends of the outer lane guides <NUM>, <NUM> can overlap the upstream ends of the lane guides <NUM>, <NUM>. In one embodiment, the lane guides <NUM>, <NUM> can be extensions of the respective lane guides <NUM>, <NUM>.

As shown in <FIG>, the articles CD, CU can move along the respective lane guides <NUM>, <NUM> in the funnel portion <NUM> from the respective combiner wheels <NUM>, <NUM> on the belt <NUM> of the main conveyor <NUM>. Once the lane guides <NUM>, <NUM> converge, the articles CD, CU can move along one or both of the lane guides <NUM>, <NUM> as they guide the articles in the output lane <NUM> to an output conveyor <NUM> and to the downstream end <NUM> of the system <NUM>. The output conveyor <NUM> can be a belt conveyor or any other suitable conveyor apparatus.

In operation, the foil down articles CD move in the first input lane <NUM> from the upstream end <NUM> of the system <NUM> along one or both of the lane guides <NUM>, <NUM> onto the main conveyor <NUM>. Similarly, the foil up articles CU move in the second input lane <NUM> from the upstream end <NUM> along one or both of the lane guides <NUM>, <NUM> onto the main conveyor <NUM>. In the illustrated embodiment, as the articles CD, CU move on the main conveyor <NUM> in the machine direction M, the articles move past the downstream end of the inner lane guides <NUM>, <NUM> (e.g., where the inner lane guides <NUM>, <NUM> converge at the divider <NUM>) and then the foil down articles CD move between the outer lane guide <NUM> and the divider <NUM> and the foil up articles CU move between the outer lane guide <NUM> and the divider <NUM>. The articles CD, CU continue to move on the main conveyor <NUM> through the lane combiner <NUM> where the foil down articles CD in the first input lane <NUM> sequentially engage the first combiner wheel <NUM> and the foil up articles CU in the second input lane <NUM> sequentially engage the second combiner wheel <NUM>.

In one embodiment, one of the foil down articles CD can engage a peak <NUM> of the first combiner wheel <NUM> as that peak <NUM> moves into the first input lane <NUM> (e.g., see the article CD in position P1 in <FIG>). As that peak <NUM> moves through the first input lane <NUM>, the main conveyor <NUM> urges the foil down article CD in the machine direction M so that the article CD engages, e.g., is at least partially received by, a recess <NUM> adjacent the peak <NUM> that is moving through the first input lane <NUM> (e.g., see the article CD in position P2 in <FIG>). The foil down article CD in the position P2 is now received in the recess <NUM> between two peaks <NUM> and is moved in the first input lane <NUM> by the first combiner wheel <NUM> as the recess <NUM> moves through the first input lane <NUM>.

In one embodiment, the combiner wheels <NUM>, <NUM> can rotate at a rate so that the articles CD, CU are moved by the respective combiner wheels <NUM>, <NUM> at a different speed than the belt <NUM>, (e.g., the combiner wheels <NUM>, <NUM> can move the articles slower or faster than the belt <NUM>). In this regard, the main conveyor <NUM> can move faster than the combiner wheels <NUM>, <NUM> so that the articles CD, CU move faster in the funnel portion <NUM> of the output lane <NUM> than the articles CD, CU in the lane combiner <NUM>, e.g., because the rotational engagement of the combiner wheels <NUM>, <NUM> with the respective articles CD, CU regulates the linear speed of the articles CD, CU, which can cause the articles CD, CU to slide along the belt <NUM> when engaged with the respective combiner wheels <NUM>, <NUM>. Such a configuration can be provided, for example, to provide clearance between one or more articles to facilitate positioning of articles on the system <NUM>, to form product groupings of preselected number/size, to accommodate disparate timing of components of the system <NUM>, to provide opportunities for visual inspection or manual adjustment, etc. Alternatively, the combiner wheels <NUM>, <NUM> can move the articles at a similar or same rate as the belt <NUM>.

In one embodiment, the main conveyor <NUM> can move faster than the combiner wheels <NUM>, <NUM> so that the articles CD, CU move faster in the funnel portion <NUM> of the output lane <NUM> than the articles CD, CU in the lane combiner <NUM> (e.g., because the rotational engagement of the combiner wheels <NUM>, <NUM> with the respective articles CD, CU regulates the linear speed of the articles CD, CU). This faster movement of the articles CD, CU in the output lane <NUM> can help provide clearance between the articles in the output lane <NUM> and the subsequent article released by the combiner wheels <NUM>, <NUM>.

Once the leading peak <NUM> of the recess <NUM> that is engaging the article CD rotates out of the first input lane <NUM>, the article CD can move out of the recess <NUM> and into the funnel portion <NUM> of the output lane <NUM> on the main conveyor <NUM> (e.g., see the article CD in the position P3 in <FIG>). In the illustrated embodiment, while the first combiner wheel <NUM> is moving a particular foil down article CD in the first input lane <NUM> (e.g., the article CD in position P2 in <FIG>), the second combiner wheel <NUM> receives in a respective recess <NUM> a particular foil up article CU that is slightly upstream with respect to that foil down article CD (e.g., the article CU in position P4 is slightly upstream from the article CD in position P2 in <FIG>). As the article CD is moved into the output lane <NUM> (e.g., the article CD in position P3 in <FIG>), the second combiner wheel <NUM> is moving the foil up article CU (e.g., in position P5 in <FIG>) in the second input lane <NUM> into position to be moved into the output lane <NUM> subsequent to the article CD in position P3.

In this regard, with respect to the foil up article CU in position P5, the peak <NUM> of the second combiner wheel <NUM> that is retaining that article in the recess <NUM> is moving through the slot <NUM> in the outer lane guide <NUM> as shown in <FIG> so that the main conveyor <NUM> can move the article CU in position P5 out of the recess <NUM> and into the output lane <NUM> subsequent to the article CD in position P3 that was previously moved into the output lane <NUM>.

The aforementioned out of phase rotation of the combiner wheels <NUM>, <NUM> combines and moves the articles CD, CU into the output lane <NUM> from the first input lane <NUM> and then from the second input lane <NUM> so that the articles CD, CU alternate in sequence in the output lane <NUM> between foil down articles CD from the first input lane <NUM> and foil up articles CU from the second input lane <NUM> to form the combined plurality of articles <NUM>. The main conveyor <NUM> can move the combined plurality of articles <NUM> into the output lane <NUM>, which can then move the alternating articles CD, CU in the downstream direction to the output conveyor <NUM> to the downstream end <NUM> of the system <NUM>. Subsequently, the articles can be further processed (e.g., wrapped, loaded into cartons, etc.).

It will be understood that the above-described operation of the lane combiner <NUM> that moves a first article CD from the first input lane <NUM> into the output lane <NUM> sequentially followed by a second article CU from the second input lane <NUM> can be repeated any desired number of times, e.g., such that a third article CD from the first input lane <NUM> is engaged by the first combiner wheel <NUM> and moved into the output lane <NUM> sequentially behind the second article CU and such that a fourth article CU from the second input lane <NUM> is engaged by the second combiner wheel <NUM> and moved into the output lane <NUM> sequentially behind the third article CD, etc..

Within the scope of protection as defined by the claims the articles CD, CU could be otherwise combined into a single lane. For example, the foil up articles CU could be moved in the first input lane <NUM> and the foil down articles CD could be moved in the second input lane <NUM> (e.g., as shown in <FIG>). In another example, the lane combiner <NUM> could be configured to move more than one article at a time from each input lane <NUM>, <NUM> (e.g., so that orientation of the articles in the output lane <NUM> alternates at every two or more articles).

<FIG> is an isometric view of a conveyor portion of a system and method <NUM> for conveying/arranging articles or containers C for being loaded into cartons (not shown) according to a second exemplary embodiment of the invention. The second exemplary embodiment can include one or more features that are substantially the same or substantially similar to those described above with regard to the first exemplary embodiment, and like or similar features are designated with like or similar reference numbers.

As shown in <FIG> and <FIG>, the system <NUM> has a lane combiner <NUM> with respective first and second combiner wheels <NUM>, <NUM> that can have a different configuration than the combiner wheels <NUM>, <NUM> of the first exemplary embodiment. In addition, the combiner wheels <NUM>, <NUM> are positioned closer together in a combination area <NUM> of the lane combiner <NUM>. It will be understood the combiner wheels <NUM>, <NUM> can have a different configuration and/or positioning, provided that they fall within the scope of protection as defined by the claims.

As described herein, the input lanes <NUM>, <NUM> are each in communication with and positioned upstream relative to a combination area <NUM> that is in communication with and positioned upstream from an output lane <NUM>. In this regard, the first plurality of articles CD and the second plurality of articles CU can be moved in a downstream direction to the lane combiner <NUM> in a manner similar to that described above with regard to the system <NUM>.

The output lane <NUM> of the system <NUM> can include respective first and second lane guides <NUM>, <NUM> that at least partially define the combination area <NUM> therebetween and do not include the funnel portion of the first exemplary embodiment. Rather, the arrangement of the combiner wheels <NUM>, <NUM> in the combination area <NUM> can obviate any additional need for a funnel portion, as described further below.

As shown in <FIG> and <FIG>, the combination area <NUM> of the lane combiner <NUM> is defined at a downstream end <NUM> of the divider <NUM> and between the outer lane guides <NUM>, <NUM>. In one embodiment, the outer lane guides <NUM>, <NUM> can include cutouts <NUM> extending to their respective downstream ends <NUM>, and the cutouts <NUM> can be configured such that at least a portion of the respective the combiner wheels <NUM>, <NUM> extend therethrough.

Two guide brackets <NUM>, <NUM> can extend along the combination area <NUM> from the upstream ends of the lane guides <NUM>, <NUM> of the output lane <NUM> to the downstream ends <NUM> of the outer lane guides <NUM>, <NUM> and can overlap with portions of the outer lane guides <NUM>, <NUM>. Each of the guide brackets <NUM>, <NUM> can include two plates <NUM> connected by a spacer element <NUM>. In one embodiment, the spacer element <NUM> can be connected to the upstream end of the respective lane guide <NUM>, <NUM>. The spacer element <NUM> can form a gap between the plates <NUM> to provide clearance for the respective combiner wheels <NUM>, <NUM>. Each of the plates <NUM> can include/define a respective sloped edge <NUM> (broadly, respective "first sloped surface" and "second sloped surface") that are arranged to converge toward one another and that can guide the articles CD, CU from the combination area <NUM> to the output lane <NUM> as the combiner wheels <NUM>, <NUM> move the articles CD, CU through the combination area <NUM>.

The first combiner wheel <NUM> is shown in <FIG> and includes a plurality of peaks <NUM> with a plurality of recesses <NUM> and a plurality convex surfaces <NUM> interposed with the peaks <NUM>. In one embodiment, the recesses <NUM> can be curved (e.g., can have a concave curved surface) to complement the curved sides S of the articles C and each recess <NUM> can extend from the adjacent convex surface <NUM> to the adjacent peak <NUM> and can be sized to receive and engage a respective article C (e.g., so that the concave surface of the recess <NUM> extends partially around the side S of the article).

In the illustrated embodiment, each of the convex surfaces <NUM> extends from one of the peaks <NUM> to the adjacent recess <NUM> and defines an elongate (e.g., relative to the recesses <NUM>), convex curve. In one embodiment, each convex surface <NUM> can define a radius of curvature R1 that is larger than a radius of curvature R2 defined by the respective recesses <NUM>.

As shown in <FIG>, the combiner wheel <NUM> has four peaks <NUM>, four recesses <NUM>, and four convex surfaces <NUM>. Alternatively, the combiner wheel <NUM> could have any suitable number of peaks <NUM>, recesses <NUM>, and convex surfaces <NUM>. As shown in <FIG>, the second combiner wheel <NUM> is similar to the first combiner wheel <NUM> except that the first combiner wheel <NUM> is configured for rotating in a counterclockwise direction CCW and the second combiner wheel <NUM> is configured for rotating in a clockwise direction CW. Alternatively, one of the combiner wheels <NUM>, <NUM> could be considered to be upside-down with respect to the other.

As shown in <FIG> and <FIG>, the combiner wheels <NUM>, <NUM> rotate on respective axes <NUM> and extend into the combination area <NUM> (e.g., through slots <NUM> in the outer lane guides <NUM> and the gaps formed between the plates <NUM> of the guide brackets <NUM>, <NUM>). In one embodiment, the combiner wheels <NUM>, <NUM> are rotated by a motor (not shown) via gears so that the first combiner wheel <NUM> rotates in the counterclockwise direction CCW as viewed from above and the second combiner wheel <NUM> rotates in the clockwise direction CW as viewed from above as shown in Figs. <NUM>-<NUM>. Accordingly, the peaks <NUM>, the recesses <NUM>, and the convex surfaces <NUM> of the combiner wheels <NUM>, <NUM> move in the machine direction M through the combination area <NUM>.

As shown in <FIG>, the centers of the combiner wheels <NUM>, <NUM> are aligned on the lateral axis L1 that extends transversely across the width of the main conveyor <NUM>, generally perpendicular to the machine direction M). The combiner wheels <NUM>, <NUM> are out of phase with respect to one another, wherein the peak <NUM> of one of the combiner wheels <NUM>, <NUM> moves through the combination area <NUM> followed by, e.g., at a different point in time than, the peak <NUM> of the opposing combiner wheel <NUM>, <NUM>.

As shown, each of the recesses <NUM> is opposed by a convex curve <NUM> of the opposing combiner wheel as the recess <NUM> and the convex curve <NUM> move through the combination area <NUM>, as the convex curve <NUM> moves through the combination area <NUM> ahead of the respective recess <NUM> to facilitate the retention of a respective article CD, CU in the respective recess <NUM> through the combination area <NUM>. Accordingly, in one embodiment, the first combiner wheel <NUM> is arranged for engaging and receiving a move a foil down article CD (broadly, "first article") from the first input lane <NUM> in the first recess <NUM> and moving the first article CD into the output lane <NUM>, which can be sequentially followed by a foil up article CU (broadly, "second article") from the second input lane <NUM> that can be engaged and received by the second combiner wheel <NUM> and moved into the output lane <NUM> after the first article CD.

In this regard, at a selected moment in time, the first combiner wheel <NUM> can be positioned at a first rotational orientation RP1 about the respective axis <NUM> in which a first recess <NUM> of the first combiner wheel <NUM> is positioned in the combination area <NUM> and is offset from a second recess <NUM> of the second combiner wheel <NUM> that is positioned in the combination area <NUM> when the second combiner wheel <NUM> is positioned at a second rotational orientation RP2 about the respective axis <NUM> that is different from the first rotational orientation RP1. In one embodiment, when the first recess <NUM> of the first combiner wheel <NUM> is positioned in the combination area <NUM>, a peak <NUM> of the second combiner wheel <NUM> extends at least partially across the second input lane <NUM>. Similarly, in one embodiment, when the first recess <NUM> of the second combiner wheel <NUM> is positioned in the combination area <NUM>, a peak <NUM> of the first combiner wheel <NUM> extends at least partially across the first input lane <NUM>.

In operation, the foil down articles CD move in the first input lane <NUM> from the upstream end <NUM> of the system <NUM> along one or both of the lane guides <NUM>, <NUM> onto the main conveyor <NUM>. Similarly, the foil up articles CU move in the second input lane <NUM> from the upstream end <NUM> along one or both of the lane guides <NUM>, <NUM> onto the main conveyor <NUM>. In the illustrated embodiment, as the articles CD, CU move on the main conveyor <NUM> in the machine direction M, the articles move past the downstream end of the inner lane guides <NUM>, <NUM> (e.g., where the inner lane guides <NUM>, <NUM> converge) and then the foil down articles CD move between the outer lane guide <NUM> and the divider <NUM> and the foil up articles CU move between the outer lane guide <NUM> and the divider <NUM>.

The articles CD, CU continue to move on the main conveyor <NUM> through the lane combiner <NUM> where the articles CD, CU sequentially and alternatingly engage the combiner wheels <NUM>, <NUM>. In one embodiment, the combination area <NUM> can be devoid of the divider <NUM>, e.g., a downstream end <NUM> of the divider <NUM> can abut or be spaced upstream from the combination area <NUM>.

In one embodiment, one of the foil down articles CD that is adjacent the downstream end <NUM> of the divider <NUM> can engage a recess <NUM> of the first combiner wheel <NUM> (e.g., see the article CD in position P10 in <FIG>) while the foil up article CU adjacent the downstream end <NUM> of the divider <NUM> can engage a convex surface <NUM> of the second combiner wheel <NUM> (e.g., see the article CD in position P11 in Figs. <NUM> and <NUM>).

As the combiner wheels <NUM>, <NUM> rotate, the convex surface <NUM> of the second combiner wheel <NUM> slides against the article CU in the P11 position, preventing the articles CU in the second input lane <NUM> from advancing (e.g., due to the motion of the belt <NUM>) into the combination area <NUM> while the article CD in the P10 position is captured by the recess <NUM> of the first combiner wheel <NUM>, which can move the article CD into the output lane <NUM> (e.g., see the article CD in position P12 in Figs. <NUM> and <NUM>). As the foil down article CD is moved through the combination area <NUM>, the subsequent article CD in the input lane <NUM> can engage the convex surface <NUM> subsequent to the recess <NUM> that engaged the article CD in the P10 position. As shown in Figs. <NUM> and <NUM>, an article CU in a position P13 is engaged between a recess <NUM> of the second combiner wheel <NUM> and a convex surface <NUM> of the combiner wheel <NUM> as the combiner wheels rotate and move the article CU in position P13 through the combination area <NUM>.

As the combiner wheels <NUM>, <NUM> rotate to move the articles CD, CU to the downstream end of the combination area <NUM>, the articles engage the sloped edges <NUM> of the guide brackets <NUM>, <NUM>, which guide the articles CD, CU into the output lane <NUM> as the articles move on the belt <NUM> out of the recesses <NUM> of the combiner wheels <NUM>, <NUM>.

In this regard, the combiner wheels <NUM>, <NUM> rotate to combine and move the articles CD, CU into the output lane <NUM> so to form the combined plurality of articles <NUM> in which the articles alternate between the foil up articles CU and the foil down articles CD in sequence. The articles move on the belt in the output lane <NUM> in the downstream direction from the lane combiner <NUM> to the output conveyor <NUM>. In this regard, the system <NUM> can be included in a continuous packaging machine for packaging the articles C for storage, shipping, sale, etc. For example, the packaging machine can continuously or substantially continuously feed articles C to the system <NUM>, which conveys the articles C as described below, which can then be transferred, for example, to a carton or container to form a package.

The above-described systems <NUM>, <NUM> for receiving the articles C from two inputs with opposing orientations and then combining the inputs into a single lane so that the articles alternate between the two orientations can be more reliable and faster than, for example, a system that receives the articles in a single input all having the same orientation and that reorients every other article to achieve an output with articles in alternating orientations. For example, such a system that is devoid of the lane combiner <NUM>, <NUM> of the respective systems <NUM>, <NUM> can have problems with reorienting the articles, which can slow the process and/or result in output that is not consistent in the alternating orientation of the articles, resulting in efficiency losses. In contrast, the systems <NUM>, <NUM> obviate any need to reorient articles therealong. Rather, the articles can be input into the second input lanes <NUM>, <NUM> and <NUM>, <NUM> of the respective systems <NUM> in respective desired orientations.

Claim 1:
A method of conveying articles (CD,CU), , comprising:
moving a first plurality of articles (CD) in a first input lane (<NUM>) in a downstream direction to a lane combiner (<NUM>; <NUM>);
moving a second plurality of articles (CU) in a second input lane (<NUM>) in the downstream direction to the lane combiner; and
operating the lane combiner to combine the first plurality of articles and the second plurality of articles into a combined plurality of articles (<NUM>) in an output lane (<NUM>; <NUM>),
the operating the lane combiner comprises engaging a first article from the first plurality of articles with a first combiner wheel (<NUM>; <NUM>), engaging a second article from the second plurality of articles with a second combiner wheel (<NUM>; <NUM>) that is out of phase with the first combiner wheel, rotating the first combiner wheel to move the first article into the output lane, rotating the second combiner wheel to move the second article into the output lane after the first article, and the combined plurality of articles (<NUM>) comprises the first article (CD) and the second article (CU) in sequence,
characterized in that the first article is in an inverted orientation relative to the second article.