Patent Description:
Folding cartons are used in a wide range of industries for packaging products. Cartons are generally manufactured on a production line by folding and gluing carton blanks using a folding-gluing machine. The cartons coming out of such folding-gluing machine are usually disposed to form a continuous row on an output conveyor, which receives the cartons on its upper surface as it advances. The cartons are then arranged in an overlapping manner where they are partially positioned on top of one another. The row of overlapping cartons forms what is called hereafter a continuous shingled stream. The cartons are then also in a flat configuration, namely in a configuration where the various panels of each carton are flat folded to essentially eliminate or minimize the entire internal volume thereof. The cartons are flat folded to optimize the space for their transportation and storage prior to their initial use, among other things. The cartons are generally shipped from a manufacturer to a packager in containers, for instance shipping boxes or bins. The packager often has its own machinery to bring the collapsed cartons into their final expanded shape so as to create an internal load volume for receiving a given product or for a given purpose. This process can also be done manually by the packager, at least in part. Other methods and situations are possible as well. The cartons can also be packaged or bundled for transportation or storage without necessarily being inserted into containers such as boxes or bins. Other variants are possible as well.

Cartons can be inserted into containers at a packing station, which is often located at the end of a production line. This loading process can be done manually by one or more operators, with or without mechanical assistance, or using a fully automated handling system.

Each container that may be used for shipping or storing cartons can hold a given number of these cartons and in many implementations, the cartons are automatically counted at some point to ensure that each container or the like will receive the proper number of cartons. They are generally counted prior to their arrival at the packing station, often at the outlet of the folding-gluing machine itself before the continuous shingled stream is created. The count is required to determine where begins or ends each group of counted cartons. These groups are called batches hereafter. The continuous shingled stream will be segmented at some point, generally at the packing station, and each container will receive one or more of these batches.

Counting the cartons once the continuous shingled stream is formed can sometimes be done, but this is often undesirable because it can increase costs and complexity of the equipment, among other things. Likewise, manually counting carton, for instance at the packing station, is often very difficult to implement and generally creates numerous challenges unless the production rate is relatively small.

Different approaches are possible for showing the demarcations between the batches in a continuous shingled stream. One possible approach is to separate the continuous shingled stream into a series of discontinuous shingled streams, each corresponding to a batch and being spaced apart from the preceding and the successive one, before they reach the packing station. This approach, however, requires having an additional handling system to carry out the separation process somewhere between the folding-gluing machine and the packing station, thereby adding costs and increasing the required floor space, among other things.

Another possible approach is to have a printing system that can put a small symbol or the like on the first or last carton of each batch within a continuous shingled stream so as to show where to separate the batches from one another at the packing station. If required, the symbol on the marked cartons can be made using an ink visible only under an ultraviolet (UV) light source. There will then be a way to see the symbols on the marked cartons at the packing station and this will provide a visual indication to be seen by a manual operator by means of a light source, for instance a UV light source if the ink can only be seen with it, or by means of a suitable electronic sensor when a fully automated system is provided. Using a printing system, however, will add costs and it may even be undesirable in some cases. For instance, a packager may not always find that having a symbol of some of the cartons is acceptable, even if it can only be seen under a UV light. The material of the cartons may also prevent the ink from suitably adhering or may create other issues. Among other things, some of the symbols could be difficult or even impossible to see once the cartons arrive at the packing station, for instance if they were unexpectedly removed from the surface of the cartons after a brief contact of this surface with an adjacent carton or with a given piece of equipment at some point along the transport circuit. Losing the count of the cartons, even just sporadically, will most likely result in errors in the quantity of cartons being inserted in some of the containers or will require the production line to be stopped for manually recounting the cartons, thereby creating undesirable delays decreasing the productivity.

Another possible approach is to laterally offset the position of some of the cartons for showing the demarcations between the batches within a continuous shingled stream. The cartons coming out of the output conveyor at the outlet of a folding-gluing machine in a continuous shingled stream are generally identically aligned and orientated. Periodically moving some of the cartons edgewise over a given distance, for instance about <NUM>, can mark the beginning or the end of each batch, thereby indicating where the continuous shingled stream must be separated into batches at the packing station. This solution, among other things, does not require using a costly handling system to physically separate a continuous shingled stream into a series of discontinuous shingled streams, before the cartons reach the packing station, or using a printing system to mark the transition between the batches. However, implementing this approach can be challenging because the visual clues provided by the edgewise offset positioning of some of these cartons can easily be lost. Among other things, the marking cartons can move back into alignment or almost into alignment with the others. Cartons that are relatively stiff and that have surfaces with a high degree of smoothness can be prone to this problem. Other factors can also be involved, for instance the configuration of the equipment to handle the shingled stream.

The outer surfaces of folding cartons are generally very smooth because this smoothness is often desirable for different reasons. However, this characteristic also tends to decrease the friction between two adjacent cartons within the shingled stream. The relatively lightweight of each carton, combined with the fact that they are semirigid articles with outer surfaces having a relatively high-degree of smoothness, can exacerbate the tendency of the offset cartons to move back into an aligned position very easily at some point of the transport circuit. Other factors, such as cyclic accelerations and decelerations of the conveyors carrying the shingled stream as well as vibrations generated by the numerous associated mechanisms, may also increase the tendency. Hence, the position offset approach often imposes its own challenges.

Folding cartons are often made using sheets of materials such as cardboard, corrugated cardboard or microplate cardboard, to name just a few. They generally have at least two major sides and depending on the materials as well as the thickness of these materials, some cartons can be easily damaged if they are subjected to even a slight bending beyond a critical angle, often less than <NUM> degrees from the median plane of the carton. Overly bending these cartons can cause a generally permanent and aesthetically undesirable deformation, such as a crease, on at least one of their major sides. There is thus often limits imposed on how folding cartons can be manipulated by the repositioning equipment.

Cartons have at least a marginal flexibility, some more than others. Stiffness is generally a desirable property in most instances since it provides strength and reduces the propensity of the cartons to bulge under the weight when they are used. In this context, folding cartons can be considered as being semirigid. Among other things, they are far more rigid than a sheet of paper or even an article consisting of numerous sheets of paper assembled such as a newspaper or a magazine, but they are typically not hard and sturdy as would be a sheet of metal of a similar thickness.

Many implementations require that the cartons be stacked vertically at the packing station, thus that these cartons are in an upright position. This can facilitate the handling of the batches, for instance their insertion into containers or the like. The cartons must then be repositioned accordingly at some point along their transport circuit. The real challenge is to find a suitable and versatile approach.

<CIT> discloses a device for delivering and packaging folded boxes in an overlapping shingled relationship. Some of the folded boxes can be shifted laterally or sidewise for delimiting the batches. However, the device requires that the incoming and outgoing conveyors be disposed perpendicularly. This may not always be possible or suitable in some implementations, particularly if the floor space is very limited. The part of the device provided to pivot the folded boxes about a central axis is also relatively long.

There is some room for further improvements in this area of technology.

Documents <CIT>, <CIT>, <CIT>, <CIT>, <CIT> and <CIT> disclose also various devices for delivering and/or packaging folded boxes or flexible sheets.

The proposed concept relates to a repositioning station for handling a continuous shingled stream of overlapping semirigid planar articles such as folding cartons.

In one aspect, there is provided a repositioning station for a continuous shingled stream of overlapping semirigid planar articles in which the articles, being carried upon an incoming conveyor in a flat configuration and in a facedown position, enter the repositioning station in a first horizontal direction and then transported by the repositioning station in a second horizontal direction onto an outgoing conveyor to form a stack with the articles in an upright position that is carried away upon the outgoing conveyor in a third horizontal direction, the repositioning station defining a transport circuit and including: a lateral deviation assembly located at an inlet of the repositioning station, the lateral deviation assembly including a plurality of lengthwise-disposed roller units along which the transport circuit follows a generally ellipsoidal deviation path to veer the shingled stream from the first direction to the second direction and also to pivot the articles in the shingled stream from the facedown position to the upright position about a curvilinear axis coinciding with an innermost and bottommost boundary of the transport circuit throughout the lateral deviation assembly.

In another aspect, there is provided a repositioning station as described, shown and/or suggested herein.

In another aspect, there is provided a system for handling a continuous shingled stream, which system is as described, shown and/or suggested herein.

In another aspect, there is provided a method of handling a continuous shingled stream, which method is as described, shown and/or suggested herein.

More details on the different aspects of the proposed concept and the various possible combinations of technical characteristics will become apparent in light of the following detailed description and the corresponding figures.

<FIG> is a semi-schematic view illustrating a generic example of a semirigid planar article, in this case a folding carton <NUM>. The illustrated generic carton <NUM> is just one example among a wide range of possibilities. It is also important to understand that the articles are not necessarily limited to folding cartons since other types of articles could be repositioned as presented herein. The following detailed description and the appended figures present the articles as being cartons but this is only for the sake of simplicity.

Planar articles such as the carton <NUM> shown in <FIG> are said to be semirigid because the main panels have a relatively limited flexibility, and sometimes only a marginal flexibility, but they are not totally inflexible. They can be made of material such as cardboard, compact fiberboard, corrugated cardboard, plastics, micro flute cardboard, etc. Some cartons can be made of more than one material. Other materials are possible as well.

The generic carton <NUM> depicted in <FIG> represents a carton in a flat configuration coming out of a folding-gluing machine on a production line. Cartons manufactured by a folding-gluing machine are generally transported over a conveyor at its exit. The main panels of the carton <NUM> are then flat folded onto one another, thereby essentially eliminating or almost eliminating the internal volume thereof to minimize the space for its transportation and storage prior to the initial use. The cartons <NUM> can still have a small internal volume therein when flat folded because of the elasticity of some of its parts and still be considered having a flat configuration.

The carton <NUM>, in a flat configuration as shown in <FIG>, has a length, a width and a thickness. In this generic example, the length corresponds to the X-axis of the coordinate system depicted in <FIG>, the width corresponds to the Y-axis and the thickness to the Z-axis. The thickness is a significantly smaller dimension than the length and the width in this example. Axes X and Y define the median plane of the carton <NUM>. This carton <NUM> also includes four outer edges defining a medial plane, namely edges <NUM>, <NUM>, <NUM> and <NUM>, that are substantially straight and uninterrupted in this illustrated example. When the carton <NUM> is unfolded for its first use, the X-axis will be oriented vertically upwards. Until then, the carton <NUM> will be kept in its flat configuration. Other configurations and arrangements are possible. Among other things, while the carton <NUM> shown in <FIG> is more or less rectangular and has uninterrupted straight edges, other shapes and configurations are possible. For instance, one or more of the edges of a carton may be non-linear or discontinuous. The exact construction or configuration of the carton <NUM>, including the proportions between its length, its width, and its thickness, as well as the correlations between these dimensions and the X-, Y- and Z-axes, can be different in some implementations. Other variants are possible as well.

<FIG> is a semi-schematic view illustrating a generic example of a continuous shingled stream <NUM> of overlapping cartons <NUM>. These cartons <NUM> are in a facedown position. This represents, for instance, cartons being transported towards a packing station to be inserted into containers. The cartons <NUM> are juxtaposed in a single row, and the length of the interval between two immediately adjacent cartons <NUM> is called the pitch.

It should be noted that <FIG> only includes a limited number of schematically depicted cartons <NUM> for the sake of simplicity. In an actual implementation, the shingled stream <NUM> generally remains uninterrupted from the beginning to the end of a production cycle, which can often extend over many hours, even more. The cartons <NUM> in the shingled stream <NUM> can be identical or similar to the one shown in <FIG>, or they can be completely different, depending on the actual implementation. Other configurations and arrangements are possible. Among other things, the shingled stream <NUM> does not have a minimum time duration to be considered as continuous and a production cycle can be relatively short in some instances. Other variants are possible as well.

The cartons <NUM> within the illustrated shingled stream <NUM> of <FIG> simply rest by gravity on a conveyor, for instance the horizontal upper surface of an endless belt conveyor <NUM>, as schematically depicted. The shingled stream <NUM>, when it is carried upon the conveyor <NUM>, generally advances in a substantially horizontal and rectilinear direction depicted by arrow <NUM>. As can be seen, the bottom surface of each carton <NUM> is only partially in contact with the conveyor <NUM> because each carton <NUM> overlaps an immediately adjacent carton <NUM>. Only the initial carton of a continuous shingled stream generally lies entirely on the upper surface of the conveyor <NUM>, for instance at the beginning of a new production cycle. The motion of the shingled stream <NUM> can be stopped and resumed from time to time, if required, but the shingled stream <NUM> will remain generally unchanged. Variants are possible as well.

Assuming that the cartons <NUM> provided in the shingled stream <NUM> of <FIG> are all configured like the one depicted in <FIG>, the X-axis is parallel to the direction <NUM> and the edges <NUM>, <NUM> are both longitudinally extending lateral edges. The Y-axis is then perpendicular to the direction <NUM> and the edges <NUM>, <NUM> are both transversal edges, with the edge <NUM> being the leading edge <NUM> and the edge <NUM> being the trailing edge in this example. The trailing edge <NUM> is the one that engages the upper surface of the conveyor <NUM> in <FIG>. Other configurations and arrangements are possible. Among other things, the cartons <NUM> could be oriented or disposed differently within the shingled stream <NUM>, for instance having an orientation where the edge <NUM> is the leading edge and the edge <NUM> is the trailing edge. Other kinds of conveyors can be used, and the conveyor <NUM> may not necessarily be an endless belt conveyor in all implementations. For instance, some implementations may include one or more conveyors having a series of transversally disposed spaced apart rollers. The top of these rollers then forms the equivalent of an upper surface. Other variants are possible as well.

<FIG> further shows that one of the cartons <NUM>, referred to hereafter as the carton <NUM>' for the sake of explanation, is laterally offset in position compared to the others since it extends out from a lateral side of the shingled stream <NUM>, namely in a direction perpendicular to direction <NUM> in <FIG>. The other cartons <NUM> have all their edges in registry with one another in this example. The edgewise offset position of the carton <NUM>' was made on purpose at an upstream location to provide a visual indication of where a corresponding batch of cartons ends or begins, each batch including a predetermined number of cartons <NUM>. The cartons <NUM> were previously counted using, for instance, an optical system or any other suitable system or method. The cartons <NUM> may be counted and offset in position at or near the exit of the folding-gluing machine when they are still spaced apart from one another and just before a continuous shingled stream is formed. This often makes counting cartons easier, less expensive, and more accurate than any other method of counting the cartons in a shingled stream. The batches of cartons <NUM> will be put into containers at the packing station. Each container will receive one or more of these batches. Ultimately, the goal is that each container holds the right number of cartons, this being generally a constant number when a same model of carton is put into containers having the same capacity. The capacity of the containers can nevertheless vary during the packing process, for instance because of a change in the size of the containers provided at the packing station or because the density of the cartons <NUM> in the containers is modified for some reason. The number of counted cartons <NUM> in each upcoming new batch can be adjusted at any time within the same shingled stream. This can be done by simply changing the number of cartons <NUM> between two successive edgewise offset cartons <NUM>', and also by synchronizing a change in the size of the containers being used at the packing station with the arrival of these batches, if required. Other configurations and arrangements are possible.

Containers for receiving the cartons <NUM> can be shipping containers, for instance receptacles such as boxes or bins having an open side that can be closed once the cartons <NUM> were inserted. Other kinds of containers are possible in some implementations. A container could consist for instance of one or more straps keeping the cartons <NUM> together, with or without any other parts, or an envelope such as a plastic wrapping or the like. Another example can be a pallet on which the batches of cartons <NUM> are put, the batches being separated from one another by a corresponding spacer or by varying the orientation of adjacent batches. Many other approaches or combination of approaches are possible as well.

<FIG> is an isometric view illustrating an example of a system <NUM> having an example of a repositioning station <NUM> in accordance with the proposed concept. It shows a continuous shingled stream <NUM> of overlapping cartons <NUM> being processed. The repositioning station <NUM> can have an inlet receiving the shingled stream <NUM> being transported on the conveyor <NUM>, the conveyor <NUM> being for instance the exit of a folding-gluing machine <NUM>. This conveyor is called hereafter the incoming conveyor <NUM> since it transports the cartons <NUM> of the shingled stream <NUM> towards the repositioning station <NUM>.

The repositioning station <NUM> allows the shingled stream <NUM> to be transferred onto an outgoing conveyor <NUM>. This outgoing conveyor <NUM> can be part of a packing station <NUM>, as shown in the illustrated example. The shingled stream <NUM> is transported through the repositioning station <NUM> along a transport circuit <NUM> (<FIG>). Other configurations and arrangements are possible. Among other things, the folding-gluing machine <NUM> could be located elsewhere, and the incoming conveyor <NUM> may not necessarily receive cartons <NUM> directly from a folding-gluing machine in some implementations. Likewise, the packing station <NUM> could be located further downstream, or even elsewhere, and the outgoing conveyor <NUM> may not necessarily be part of a packing station in some implementations. Hence, the repositioning station <NUM> may operate without a folding-gluing machine or a packing station, or even both, being near the system <NUM>. The repositioning station <NUM> could also be provided as a standalone equipment, for instance for installing it on an existing system. The incoming and outgoing conveyors <NUM>, <NUM> described and illustrated herein are only examples, and the repositioning station <NUM> can be provided in a system where different kinds or models of conveyors are used. Other variants are possible as well.

The repositioning station <NUM> of <FIG> can be subdivided into two main sections, one being referred to as a lateral deviation assembly <NUM> and located at the inlet, and one being referred to as a final positioning assembly <NUM> and located at the outlet. The lateral deviation assembly <NUM> is positioned on one side of the outgoing conveyor <NUM> and be supported by a corresponding framework <NUM>, which supporting framework <NUM> can be directly attached to the supporting framework <NUM> provided under the outgoing conveyor <NUM>, as shown in the illustrated example. The final positioning assembly <NUM> of the repositioning station <NUM> can be supported by the framework <NUM>. Other configurations and arrangements are possible. Among other things, the lateral deviation assembly <NUM> or the final positioning assembly <NUM>, or even both, can be configured differently or supported using other kinds of frameworks or arrangements. Other variants are possible as well.

<FIG> is a semi-schematic isometric view illustrating how the shingled stream <NUM> is transported through the repositioning station <NUM> in the system <NUM> shown in <FIG>. The shingled stream <NUM> is thus shown without the repositioning station <NUM> and without the outgoing conveyor <NUM> for the sake of illustration. In this implementation, the shingled stream <NUM> veers to the left and the cartons <NUM> arrive on the outgoing conveyor <NUM> from its right-hand side to form a stack. As can be seen, the lateral offset cartons <NUM>' are now upwardly offset cartons <NUM>' and are still clearly marking the transitions between the batches.

<FIG> is a view similar to <FIG> but illustrating an implementation where the shingled stream <NUM> veers to the right.

<FIG> also show that the innermost edge of the cartons <NUM> follows a curvilinear axis <NUM>. The term "innermost" refers to the side of the turn. The curvilinear axis <NUM> can be substantially horizontal and uniplanar, as shown, and the lateral alignment of the carton <NUM> at the inlet can correspond to the vertical alignment at the outlet of the lateral deviation assembly <NUM>. The curvilinear axis <NUM> coincides with the innermost and bottommost boundary of the transport circuit <NUM> (<FIG>) throughout the lateral deviation assembly <NUM>. Other configurations and arrangements are possible. For instance, the transport circuit <NUM> may include a small variation of the vertical height between its inlet and outlet ends. This variation will generally be less than a few centimeters but it could possibly be more in others, for instance to clear a local obstacle on the floor or for other reasons. Other variants are possible as well.

The cartons <NUM> in the shingled stream <NUM> are in a facedown position at the inlet of the repositioning station <NUM>. The horizontal direction <NUM> forms what is called hereafter the first direction. The shingled stream <NUM> exits the repositioning station <NUM> in a second horizontal direction <NUM> onto the outgoing conveyor <NUM> as they fall by gravity thereon. The cartons <NUM> are then being in an upright position and form a stack that is carried away upon the upper surface of the outgoing conveyor <NUM> advancing in a third horizontal direction <NUM>. The incoming conveyor <NUM> and the outgoing conveyor <NUM> of <FIG> are laterally offset in position, and the first and third directions <NUM>, <NUM> can be substantially parallel to one another. The repositioning station <NUM> can thus have a first section located on the side of the outgoing conveyor <NUM> and a second section extending across and above the outgoing conveyor <NUM>, as shown. The cartons <NUM> are transported in the second direction <NUM> when the shingled stream <NUM> is in the final leg of the transport circuit <NUM>. This second direction <NUM> can be substantially perpendicular to the first direction <NUM> and thus also to the third direction <NUM>, as shown in the illustrated example. Other configurations and arrangements are possible. Among other things, although the first direction <NUM> and the third direction <NUM> have the same orientation in the example of <FIG>, the third direction <NUM> can be countercurrent with reference to the first direction <NUM> in some implementations, depending for instance on how the cartons <NUM> are positioned in the shingled stream <NUM>. <FIG> is a view similar to <FIG> but illustrating an example of an implementation where the cartons <NUM> in the shingled stream <NUM> are oriented differently and where the outgoing conveyor <NUM> carries the stacked cartons in a countercurrent direction, namely in the third direction <NUM>. Also, the degree of precision of the perpendicularity and of the parallelism between the directions <NUM>, <NUM>, <NUM> can be relatively low and the phrases "substantially parallel" and "substantially perpendicular" cover deviations of up to about <NUM> degrees. In certain implementations, the deviations can be up to about <NUM> degrees. A repositioning station <NUM> could be implemented without having the first and third directions <NUM>, <NUM> being parallel or even substantially parallel, or without having the second direction <NUM> being parallel to the first or third direction <NUM>, <NUM>. Other variants are possible as well.

<FIG> is an isometric view of the system <NUM> shown in <FIG> but taken from another viewpoint and without the shingled stream. The shingled stream is not shown only for the sake of simplicity.

The repositioning station <NUM> can include a lateral guiding device <NUM> positioned immediately upstream the inlet of the lateral deviation assembly <NUM>, as shown. This lateral guiding device <NUM> can be useful to correct the position, for instance the angular position, of the incoming cartons in order to have their innermost edge in alignment with the curvilinear axis <NUM> at the inlet of the lateral deviation assembly <NUM>. Only the marking cartons <NUM>' are not aligned by the lateral guiding device <NUM> because their offset position is intended. They are offset towards the other lateral side. Other configurations and arrangements are possible. Among other things, the lateral guiding device <NUM> can be constructed or be positioned differently in some implementations. It could also be omitted in others. The repositioning station <NUM> can process a shingled stream <NUM> where no edgewise offset cartons <NUM>' are present. Other variants are possible as well.

<FIG> is a top plan view of the system <NUM> shown in <FIG>. As can be seen, the lateral deviation assembly <NUM> includes a plurality of lengthwise-disposed roller units <NUM> along which the transport circuit <NUM> follows a generally ellipsoidal deviation path to veer the shingled stream <NUM> from the first direction <NUM> to the second direction <NUM> while simultaneously pivoting the cartons <NUM> from the facedown position to the upright position.

It should be noted that unlike existing handling systems, the position of the shingled stream <NUM> within the illustrated repositioning station <NUM> is not based on the geometric center of the cartons <NUM>. It is based instead on the innermost boundary of the transport circuit <NUM>. This feature can greatly simplify the settings to be made in the transition from one model of carton to another when the two models have dissimilar widths since the innermost boundary of the transport circuit <NUM> can remain the same. Furthermore, because the cartons <NUM> are repositioned simultaneously about two axes, the transport circuit <NUM> can be made shorter, thereby minimizing the required floor space of the equipment. Variants are possible as well.

<FIG> is a side view of what is shown in <FIG>, as viewed from the inlet of the repositioning station <NUM>. The figure shows that the curvilinear axis <NUM> in this example is horizontal.

<FIG> is an enlarged isometric view illustrating a portion of one of the roller units <NUM> provided along the lateral deviation assembly <NUM> of the repositioning station <NUM> shown in <FIG>.

Each roller unit <NUM> can include one or more motorized underside rollers <NUM> which can be collectively driven by one or more electric motors <NUM>, as shown in the illustrated example. Some of the rollers <NUM> can be directly driven through a direct coupling while adjacent ones are indirectly driven using endless belts running from one roller <NUM> to another and passing for instance through driving grooves <NUM> made on each roller <NUM>, as shown. There are two spaced-apart electric motors <NUM> for driving the underside rollers <NUM> in the illustrated example, as shown for instance in <FIG> and <FIG>. This configuration was found to be adequate in this implementation for generating the required torque for the roller units <NUM> in the lateral deviation assembly <NUM>. Adding more electric motors would generally not yield significant benefits justifying the additional costs involved. Other configurations and arrangements are nevertheless possible. Among other things, other kinds of rollers, motors or linkages can be used. Other variants are possible as well.

Each underside roller <NUM> can include multiple peripheral rings <NUM> that are spaced apart along each of them, as shown in the illustrated example. These rings <NUM> can be made of a rubbery material or any other one that can increase the friction with the outer surface of the cartons <NUM>. This can improve the driving contact and can mitigate the risks of damaging the cartons <NUM> or leaving a mark thereon. Other configurations and arrangements are possible. Among other things, this feature can be unnecessary in some implementations and could thus be omitted entirely. Other variants are possible as well.

Each roller unit <NUM> can further include an overhead roller <NUM> positioned above one or more corresponding underside rollers <NUM>, as shown for instance in the illustrated example. The overhead rollers <NUM> can apply a force on the topside of the cartons <NUM> passing through the lateral deviation assembly <NUM>. Each overhead roller <NUM> can be part of a biasing arrangement <NUM> maintaining the shingled stream <NUM> in driving engagement with the underside roller <NUM>. The biasing arrangement <NUM> can also include a cantilevered support arm <NUM> and a pneumatic actuator <NUM> that is configured and disposed to urge the corresponding overhead roller <NUM> towards the corresponding underside roller or rollers <NUM>, as shown in the illustrated example. The support arm <NUM> can pivot about a corresponding pivot axis <NUM>. One end of the actuator <NUM> can be pivotally attached to a side extension <NUM> at a rear end of the support arm <NUM>. The pressure in each actuator <NUM> can be controlled using one or more pneumatic pressure regulators or the like. Adjustments to change the kinds of cartons being handled are generally quick and straightforward with a pneumatic force-generating system. The underside roller <NUM> of the roller unit <NUM> can be supported using a holding member <NUM>, as shown. The holding member <NUM> can be mechanically connected to the other parts of the roller unit <NUM> through a main bracket <NUM>, which main bracket <NUM> is also where the support arm <NUM> is pivotally attached. Other configurations and arrangements are possible. Among other things, mechanical springs or the like could be used. The force-generating mechanism could be based only on the gravitational force, for instance using balanced weights at least for some of the roller units <NUM>. Different kinds of mechanisms can be present in a same lateral deviation assembly <NUM>. The various rollers can be constructed and arranged differently. The construction and configuration of the components such as the support arm <NUM>, the holding member <NUM> and the main bracket <NUM>, among other things, can be different. Some of these components can be omitted, replaced with other kinds of components, or integrated with other components, for instance. Other variants are possible as well.

Each overhead roller <NUM> can be made of a relatively malleable material, with multiple voids, as shown in the illustrated example. This construction is known as a no-crush wheel and the overhead roller <NUM> can generally be pressed against the cartons <NUM> without causing physical damage or visual marking. Other configurations and arrangements are possible. Among other things, the overhead rollers <NUM> can be made of other materials and no include voids. The diameter and width of the overhead rollers <NUM> can be different, for instance larger, compared to what is shown. Other variants are possible as well.

It should be noted that <FIG> shows only a portion of a roller unit <NUM> since in the illustrated example, there is one overhead roller <NUM> between two underside rollers <NUM>. In other words, a roller unit <NUM> can include two underside rollers <NUM> and one overhead roller <NUM>, as shown. The overhead roller <NUM> can be at a median position with reference to the two corresponding underside rollers <NUM>. Having fewer overhead rollers <NUM> than underside rollers <NUM> reduces the part counts, thereby lowering the manufacturing costs and complexity. Other configurations and arrangements are nevertheless possible. Among other things, the exact position of the overhead rollers <NUM> with reference to the corresponding underside rollers <NUM> can be different. Using proportionally more or less overhead rollers <NUM> is also possible, although using fewer overhead roller units <NUM>, for instance one for every three underside rollers <NUM>, can further decrease the manufacturing costs but could create complications in the handling of the shingled stream <NUM> in some situations and could increase the risks of having some cartons <NUM> sliding down near the end of the lateral deviation assembly <NUM>. Different configurations of roller units <NUM> can be present along a same lateral deviation assembly <NUM>. Other variants are possible as well.

<FIG> is an enlarged isometric view of the repositioning station <NUM> shown in <FIG>. This figure shows the transition from the lateral deviation assembly <NUM> to the final positioning assembly <NUM>. The lateral deviation assembly <NUM> ends with the last underside roller <NUM>. The final positioning assembly <NUM> can include a first transfer unit <NUM> driving one side of the cartons <NUM> when they are in an upright position. It can also include a bottom roller <NUM> to guide the innermost side of the cartons <NUM>, coming along the curvilinear axis <NUM>, over the side edge of the outgoing conveyor <NUM>, as shown, just in case some of them are too low for some reason. The final positioning assembly <NUM> can further include a second transfer unit <NUM> driving the other side of the cartons <NUM> in the final leg of the transport circuit <NUM>, as shown. Other configurations and arrangements are possible. Among other things, the first transfer unit <NUM> and the second transfer unit <NUM> can be configured and arranged differently. They can be replaced by another arrangement in some implementations. The bottom roller <NUM> can be positioned and configured differently, or it can be replaced by a curved or inclined surface or the like, or even be omitted in some implementations. Other variants are possible as well.

<FIG> is a side view illustrating only the lateral deviation assembly <NUM> of the repositioning station <NUM> shown in <FIG>. <FIG> is a view similar to <FIG> but without the overhead rollers <NUM> and the support arms <NUM> of the roller units <NUM>. <FIG> is a top plan view of what is shown in <FIG>.

<FIG> and <FIG> schematically show cartons <NUM> within the shingled stream <NUM> at different stages along the transport circuit <NUM> passing therein, where the cartons <NUM> start in a facedown position at the inlet and end in an upright position at the outlet. As aforesaid, the cartons <NUM> of the shingled stream <NUM> passing through the lateral deviation assembly <NUM>, following the portion of the transport circuit <NUM> therein, will transition from the facedown position to the upright position. They will also simultaneously veer from the first direction <NUM> to the second direction <NUM> along the way. The pivot motion from the facedown position to the upright position can be over about <NUM> degrees, as shown in the illustrated example. Likewise, the change of direction about a vertical axis can be a pivot motion over about <NUM> degrees, as shown. The lateral deviation assembly <NUM> thus causes the shingled stream <NUM> to follow a generally ellipsoidal deviation path along the transport circuit <NUM>. Other configurations and arrangements are possible. Among other things, the parallelism of the inner edge of the cartons <NUM> and the curvilinear axis <NUM> needs not necessarily to be perfect. An average misalignment up to about <NUM> degrees can generally be acceptable. Some models of cartons <NUM> coming out of a folding-gluing machine could sometimes have an average misalignment of more than <NUM> degrees, and this is one circumstance where having the lateral guiding device <NUM>, or an equivalent, could be useful. An excessive misalignment could otherwise cause undesirable reliability issues in some implementations. The vertical height of the upper surface at the end of the incoming conveyor <NUM> being about the same as the upper surface of the outgoing conveyor <NUM>, and the curvilinear axis <NUM> being substantially horizontal and uniplanar in the example, the position of the innermost edge of the cartons <NUM> can be set so that this edge will arrive just a few millimeters or even less above the upper surface over the outgoing conveyor <NUM> at the outlet of the lateral deviation assembly <NUM>. This alignment of the innermost edge of the cartons <NUM> at the inlet of the lateral deviation assembly <NUM> can correspond to the output height of the vertically oriented cartons <NUM> at the outlet of the lateral deviation assembly <NUM>. In the example illustrated in <FIG>, if the lateral guiding device <NUM> was positioned too far on the left, the curvilinear axis <NUM> could end up below the upper surface of the outgoing conveyor <NUM>, causing the leading edge <NUM> of the cartons <NUM> to potentially collide with the side of the outgoing conveyor <NUM>. On the other hand, if the lateral guiding device <NUM> was positioned too far to the right in <FIG>, the curvilinear axis <NUM> could end up too far above the upper surface of the outgoing conveyor <NUM>, thereby causing the position of the offset cartons <NUM>' to become indistinguishable from the adjacent ones when a stack is formed on the outgoing conveyor <NUM> in some implementations. Thus, the lateral guiding device <NUM> can also serve as a device for adjusting the output height at the outlet of the lateral deviation assembly <NUM>. It can nevertheless be omitted in some implementations, as aforesaid.

<FIG> shows the transport circuit <NUM> within the lateral deviation assembly <NUM> of the illustrated example being divided approximately into four sequential sections A, B, C, D. These sections are only for the sake of explanation. As shown, the carton <NUM> can pivot about a vertical axis at an increased rate in section A compared to that in the subsequent ones, in particular sections C and D. However, the carton <NUM> can pivot about the curvilinear axis <NUM> at a lower rate in section A and the rate can progressively increase thereafter in the subsequent ones. The configuration may vary from one implementation to another but in many instances, initially having an increased pivoting rate of the cartons <NUM> about a vertical axis at the beginning and pivoting the cartons <NUM> about the curvilinear axis <NUM> for the transition from the facedown position to the upstanding position at a rate that increases towards the end can minimize the floor space. Other configurations and arrangements are possible. Among other things, the sections can be configured differently. Other variants are possible as well.

<FIG> is an isometric view illustrating the first transfer unit <NUM> of the repositioning station <NUM> shown in <FIG>. This first transfer unit <NUM> drives one side of the shingled stream <NUM> onto the upper surface of the outgoing conveyor <NUM> at the outlet of the lateral deviation assembly <NUM>. It is provided on the same side as the rollers <NUM>. The first transfer unit <NUM> can include a vertically disposed endless belt <NUM>. In the example, only a planar section of the belt <NUM> is exposed and engages the shingled stream <NUM>. The belt <NUM> is supported by a plurality of rollers mounted inside the casing of the first transfer unit <NUM>. As can be seen, the first transfer unit <NUM> is configured and disposed so as to have a very small radius at the corner <NUM>. The belt <NUM> can be supported near this corner <NUM> using a roller having a very small radius. This allows the corner <NUM> to be practically at a right angle. This can be useful to minimize potential contacts with the trailing edge of the cartons <NUM> arriving on the outgoing conveyor <NUM>. The belt <NUM> of the first transfer unit <NUM> can be driven by a corresponding motor, for instance an electric motor. Other configurations and arrangements are possible. The first transfer unit <NUM> can be constructed differently, for instance without an endless belt. Another kind of motor can be used. Other variants are possible as well.

<FIG> is an enlarged isometric view illustrating the final positioning assembly <NUM> of the system <NUM> shown in <FIG> with a single carton <NUM> being present next to the first transfer unit <NUM> for the sake of illustration. The first transfer unit <NUM> is vertically positioned close to the upper surface of the outgoing conveyor <NUM> in this example.

<FIG> is a view similar to <FIG> but where the first transfer unit <NUM> is set at a higher vertical position to handle a different model of carton <NUM>. It is at a higher position because of the presence of a void at the bottom end in this model of carton. The higher position will allow each carton <NUM> to be in contact with the first transfer unit <NUM> over a longer distance. The vertical position was adjusted in this example using a slotted bracket <NUM> as well as a corresponding locking arrangement. Other configurations and arrangements are possible. Among other things, other systems for adjusting the vertical position of the first transfer unit <NUM> can be used. This kind of adjustment can also be absent in some implementations. Other variants are possible as well.

<FIG> is an isometric view illustrating the second transfer unit <NUM> of the repositioning station <NUM> shown in <FIG>. <FIG> is a top plan view what is shown in <FIG>. The second transfer unit <NUM> can transport the cartons <NUM> across the width of the outgoing conveyor <NUM> until their leading edge impinges on an end plate <NUM>. This end plate <NUM> can be part of a plate assembly <NUM>. This second transfer unit <NUM> can thus be useful to ensure that the cartons <NUM> will reach the desired position on the outgoing conveyor <NUM>. The second transfer unit <NUM> can include a vertically disposed endless belt <NUM>, as shown. This belt <NUM> is supported using a plurality of rollers. These rollers are mounted on a support structure. The belt <NUM> is driven by a motor <NUM>, for instance an electric motor or the like. Other configurations and arrangements are possible. At least some of these parts can be designed differently, or even be omitted in some implementations. Other kinds of motors can be used. Other variants are possible as well.

The second transfer unit <NUM> can include an exit roller and plate assembly <NUM>, as shown. It can form the end of the transport circuit <NUM> where the forward movement of the shingled stream <NUM> is interrupted and transfers to a movement in the third direction <NUM>. The exit roller and plate assembly <NUM> can move on a parallel axis along the transport circuit <NUM> and can be adjusted to the length of the carton <NUM>. The opening between the end plate <NUM> and the entry plate <NUM> correspond to the length of the cartons <NUM> plus an extra gap to mitigate the risks of jams. The end plate <NUM> receives the edges of the cartons <NUM> and can be mounted on a mechanically isolated part to which a vibrating device <NUM> is attached. The vibrations of the end plate <NUM> can help having a smooth transition of the shingled stream <NUM> from the second direction <NUM> to the third direction <NUM>. Other configurations and arrangements are possible. Among other things, one or more of the features presented herein can be constructed differently or be omitted entirely in some implementations. Other variants are possible as well.

The second transfer unit <NUM> can include an entry roller assembly <NUM> having a planar section where the belt <NUM> running through the second transfer unit <NUM> will be directly facing the belt of the first transfer unit <NUM>. This entry roller assembly <NUM> can also be configured for moving laterally, thereby dynamically changing the position of the planar section based on the thickness of the shingled stream <NUM>. It can include, among other things, a pneumatic actuator in which the pressure can be set to maintain the appropriate force. One side of the shingled stream <NUM> may have a relatively uneven profile and this side can be the one facing the underside rollers <NUM> and then the first transfer unit <NUM>. The shingled stream <NUM> may have an opposite side with height variations due to the carton geometry and to the pitch of the shingled stream <NUM>. This side will be the one engaged by the overhead rollers <NUM>. These overhead rollers <NUM> can shift in position and the entry roller assembly <NUM> can also adjust the position of the planar section to follow the height variations of this side of the shingled stream <NUM>. Other configurations and arrangements are possible. Some of these features can be omitted in some implementations. Other variants are possible as well.

<FIG> is a top plan view depicting an example where a few cartons <NUM> form a stack on the outgoing conveyor <NUM> at the end of the repositioning station <NUM> shown in <FIG>. <FIG> is a view similar to <FIG> but with significantly narrower cartons <NUM>.

<FIG> is an enlarged side view illustrating another example of a roller unit <NUM> for the repositioning station <NUM>. This model of roller unit <NUM> includes, among other things, a two-part support arm <NUM>. The length of the support arm <NUM> can be modified so as to change the position of the overhead roller <NUM> with reference to the pivot axis <NUM>. The distal part of the support arm <NUM>, at the end of which the overhead roller <NUM> is located, can slide with reference to the proximal part, and a locking mechanism <NUM> is provided between them to secure these two parts during operation. This locking mechanism <NUM> can include a pair of spaced apart set screws that can be untightened to slide the two parts along an intervening slot and that can be tightened to prevent them from moving relative to one another. The rotation axis <NUM> of the overhead roller <NUM> can be parallel to the longitudinal direction of the support arm <NUM>, as shown.

<FIG> is a view similar to <FIG> but showing the support arm <NUM> being shorter.

Adjusting the length of the support arm <NUM> can be useful when cartons <NUM> of various shapes and sizes are transported through the repositioning station <NUM>. Some cartons <NUM> may include voids or have protruding features. Changing the position of the overhead roller <NUM> so as to prevent these features from being damaged, or because having another position will be better, could be desirable. Other configurations and arrangements are possible. Among other things, the exact constructions of the parts and their relative position or orientation can vary from one implementation to another. The locking mechanism <NUM> can be different from the one shown and described. Other kinds of adjustments can be added to the roller unit <NUM>. Having adjustable support arms <NUM> can be omitted in some implementations. Many other variants are possible as well.

<FIG> further show that the roller unit <NUM> can include a torsion spring <NUM>. This torsion spring <NUM> replaces the pneumatic actuator <NUM> shown in <FIG>. It is provided to apply a force urging the overhead roller <NUM> towards the underside roller <NUM>. Other configurations and arrangements are possible. Among other things, the exact nature, position, and configuration of a spring system within each roller unit <NUM> can vary from one implementation to another. A roller unit <NUM> can include more than one spring, or simply relying on gravity. A spring can be provided without the support arm <NUM> being adjustable in length. Many other variants are possible as well.

<FIG> is an isometric view of the system <NUM> shown in <FIG> but where the repositioning station <NUM> is temporarily bypassed. In this implementation, the outgoing conveyor <NUM> can be aligned directly with the end of the incoming conveyor <NUM>, for instance because a particular model of cartons <NUM> being manufactured does not require any repositioning using the repositioning station <NUM>. As can be seen, the second transfer unit <NUM> was moved upwards to be out of the way of the shingled stream <NUM> passing directly from the first conveyor <NUM> to the outgoing conveyor <NUM> on its way to the packing station <NUM> or to any other downstream equipment or location. The second transfer unit <NUM> can include a supporting frame <NUM>, for instance having two opposite vertical posts and an overhead transversal horizontal beam, along which the second transfer unit <NUM> can be modified. The outgoing conveyor <NUM> is often easier to relocate than the incoming conveyor <NUM> and one can bring the outgoing conveyor <NUM> into alignment with the incoming conveyor <NUM> until the repositioning station <NUM> is needed again. Wheels can be already present under the supporting framework <NUM> to facilitate handling, and supporting legs can be used thereafter to maintain the parts in position during operation. While the possibility of creating a bypass is not directly the result of the operation of the repositioning station <NUM>, it can still be a key feature for some manufacturers because it allows them to have a repositioning station when needed but still be able to reconfigure the floor space quickly when this is required. Other configurations and arrangements are possible. Among other things, this feature can be entirely omitted in some implementations or be configured differently. Other variants are possible as well.

<FIG> is an isometric view illustrating another example of a system <NUM> where the repositioning station <NUM> includes a second transfer unit <NUM> mounted on a support frame <NUM> that can pivot with reference to a transversal bottom axis so as to create a bypass similar to the one shown in <FIG>. Opposite bottom ends of the support frame <NUM> can be pivotally attached to the supporting framework <NUM>, as shown. A lift system (not shown) can be provided, if desired, to facilitate handling or to move the whole section using an actuator or the like. Other configurations and arrangements are possible.

<FIG> is an isometric view of what is shown in <FIG> but from another viewpoint.

<FIG> further show that the first transfer unit <NUM> can include one or more rollers instead of an endless belt system. The first transfer unit <NUM> includes adjacent rollers in this illustrated example. These rollers can be similar to the rollers <NUM>. Other configurations and arrangements are possible. Among other things, the number of roller in this kind of first transfer unit <NUM> and their shape can be different. Other variants are possible as well.

<FIG> is an enlarged isometric view of the first transfer unit <NUM> shown in <FIG>. The second transfer unit <NUM> and various other parts that can be seen in <FIG> are not shown in <FIG> for the sake of illustration. <FIG> shows that the first transfer unit <NUM> can be configured as a continuity of the lateral deviation assembly <NUM>, for instance having its rollers <NUM>, <NUM> in a torque-transmitting engagement with adjacent rollers <NUM> of the lateral deviation assembly <NUM>. The two rollers <NUM>, <NUM> of this first transfer unit <NUM> can rotate about a vertical axis and van be mounted using a corresponding support casing <NUM>, as shown in the illustrated example. Other configurations and arrangements are possible. Among other things, the rollers of the first transfer unit <NUM> can be driven using their own motor or using another arrangement. They can also be supported through another kind of arrangement instead of the support casing <NUM>. The rotation axis of the rollers can be oriented differently in some implementations. Other variants are possible as well.

<FIG> is an enlarged isometric view illustrating the final positioning assembly <NUM> having a first transfer unit <NUM> as shown in <FIG>. <FIG> also shows a single carton <NUM> only for the sake of illustration. The final positioning assembly <NUM> can include a vertical side plate <NUM> extending parallel to the third direction <NUM> and located immediately after the last roller <NUM> of the first transfer unit <NUM>, as shown. Other configurations and arrangements are possible. Among other things, at least some of the features described in the present paragraph or shown in the corresponding figures, or both, can be omitted in some implementations. They can also be designed or disposed differently. Other variants are possible as well.

<FIG> is a top plan view of what is shown in <FIG>, with the exception of the carton <NUM>.

<FIG> is a top plan view similar to <FIG> but illustrating another example of a repositioning station <NUM> where the first transfer unit <NUM> includes a vertical endless belt and can be moved transversally to handle narrower cartons <NUM>.

<FIG> is a view similar to <FIG> but with significantly narrower cartons <NUM>. The stack of cartons <NUM> is now adj acent to the left side of the outgoing conveyor <NUM> with reference to the third direction <NUM>. Unlike the similar narrow stack shown in <FIG>, the cartons <NUM> in <FIG> are now close to the opposite side of the outgoing conveyor <NUM>. The first transfer unit <NUM> in <FIG> and <FIG> includes a plurality of rollers and some of these parts can be mounted on a framework that can be transversally repositioned so as to move the leading end of the first transfer unit <NUM> closer or away from the opposite side. The vertical side plate <NUM> is then also repositioned in the example. The narrower cartons <NUM> in the illustration will be carried transversally between the two transfer units <NUM>, <NUM> over a longer distance to reach their destination. This arrangement, although more complex compared to others, can be useful in some cases, for instance in an implementation where operators or the machinery at the packing station will be on this side. Other configurations and arrangements are possible. Among other things, at least some of the features described in the present paragraph or shown in the corresponding figure, or both, can be omitted in some implementations. They can also be designed or disposed differently. Other variants are possible as well.

<FIG> is a top plan view of the first transfer unit <NUM> that is configured as shown in <FIG>. <FIG> is a view similar to <FIG> but shows the first transfer unit <NUM> being configured in an extended position as shown in <FIG>.

<FIG> is an isometric view of the second transfer unit <NUM> in the repositioning station <NUM> shown in <FIG> and <FIG>.

<FIG> is a view similar to <FIG>, but from another viewpoint.

<FIG> are isometric views illustrating an example of a system <NUM> having the second transfer unit <NUM> as shown in <FIG> and <FIG> that can be moved laterally with reference to the outgoing conveyor <NUM> so as to create a bypass similar to the one shown in <FIG>. The support frame <NUM> is configured and disposed so that parts of the second transfer unit <NUM> can be moved to the side.

Claim 1:
A repositioning station (<NUM>) for a continuous shingled stream (<NUM>) of overlapping semirigid planar articles (<NUM>) in which the articles (<NUM>), being carried upon an incoming conveyor (<NUM>) in a flat configuration and in a facedown position, enter the repositioning station (<NUM>) in a first horizontal direction (<NUM>) and then transported by the repositioning station (<NUM>) in a second horizontal direction (<NUM>) onto an outgoing conveyor (<NUM>) to form a stack with the articles (<NUM>) in an upright position that is carried away upon the outgoing conveyor (<NUM>) in a third horizontal direction (<NUM>), the repositioning station (<NUM>) defining a transport circuit (<NUM>) and being characterised by including:
a lateral deviation assembly (<NUM>) located at an inlet of the repositioning station (<NUM>), the lateral deviation assembly (<NUM>) including a plurality of lengthwise-disposed roller units (<NUM>) along which the transport circuit (<NUM>) follows a generally ellipsoidal deviation path to veer the shingled stream (<NUM>) from the first direction (<NUM>) to the second direction (<NUM>) and also to pivot the articles (<NUM>) in the shingled stream (<NUM>) from the facedown position to the upright position about a curvilinear axis (<NUM>) coinciding with an innermost and bottommost boundary of the transport circuit (<NUM>) throughout the lateral deviation assembly (<NUM>).