Patent Description:
The disclosure is directed to a method of arranging articles according to claim <NUM> and a system for arranging articles according to claim <NUM>.

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. It is within the scope of the present disclosure that the above-discussed aspects be provided both individually and in various combinations.

The present disclosure generally relates to a system and method of arranging articles prior to loading the articles into cartons. The system according to the present disclosure 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 illustrate an example embodiment of a system and method <NUM> for arranging articles or containers C for being loaded into cartons (not shown) 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, and/or sale. For example, the packaging machine can continuously, substantially continuously, or intermittently (e.g., indexed) feed articles C to the system <NUM>, which arranges the articles C as described below, and then transfers the arranged articles C to a carton (not shown), wherein the carton and the articles form a package. In the illustrated embodiment, the articles C (e.g., as shown in <FIG>, <FIG>, <FIG>, and <FIG>) can be in the form of tubs or cups having tapered sides S so that the cups are narrower at their bottoms B than at their tops T. The top T of each article C can have a rim R and a lid L (e.g., a foil 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.) in a brewing system (e.g., K-Cup pods for single-cup and/or multi-cup brewing systems available from Keurig of Burlington, MA, or other suitable containers and systems).

In the illustrated embodiment, the packaging system <NUM> moves the articles C into a plurality of buckets <NUM> (<FIG>, <FIG>) moving from an upstream end <NUM> to a downstream end <NUM> generally in a machine direction M (e.g., the downstream direction) on a conveyor assembly <NUM>. In one embodiment, the articles C can be loaded into the buckets <NUM> via an article conveyor <NUM> (<FIG> and <FIG>) so that the articles C alternate between foil up (e.g., upside-up with the top T and lid L facing upwardly and the rim R positioned above the bottom B) and foil down (e.g., upside-down with the top T and lid L facing down and the bottom B positioned above the rim R). As the buckets <NUM> continue to move in the machine direction M on the conveyor assembly <NUM>, the buckets <NUM> can interact with an actuating cam assembly <NUM>, which can actuate the buckets <NUM> to at least partially arrange the articles C to be in a more compact configuration. In one embodiment, the articles C can be removed from the bucket <NUM> in the compact configuration by a robot arm (not shown) or other suitable apparatus and loaded into a carton (not shown). Subsequently, the buckets <NUM> can be returned to the upstream end <NUM> by the conveyor assembly <NUM> where the buckets can interact with a reset cam assembly <NUM> that can prepare the buckets <NUM> for receiving the articles C. In one embodiment, the actuating cam assembly <NUM> and the reset cam assembly can be mounted to respective downstream and upstream ends of a cam base plate <NUM> (<FIG> and <FIG>).

As illustrated in <FIG>, the buckets <NUM> are mounted to two belts or chains <NUM> of the conveyor assembly <NUM>, which carries the buckets <NUM> in the machine direction M on top of the conveyor assembly <NUM> and returns the buckets <NUM> from the downstream end <NUM> to the upstream end <NUM> on an underside of the conveyor assembly <NUM> in an endless loop. In one embodiment, the conveyor assembly <NUM> can include a motor <NUM> or other suitable apparatus for moving the chains <NUM>. While <FIG> shows buckets <NUM> only on the top side of the conveyor assembly <NUM>, the system <NUM> can include buckets <NUM> mounted along the entire conveyor assembly <NUM>. The conveyor assembly <NUM> could be otherwise shaped, positioned, arranged, and/or configured without departing from the disclosure.

As shown in <FIG>, the bucket <NUM> can include a base <NUM> (e.g., a base plate), a sidewall <NUM>, a translation plate <NUM>, and a plurality of fingers 127a, 127b, 127c. In addition, brackets <NUM> can be secured (e.g., bolted) to the base <NUM> and can extend downwardly from the base <NUM> for being secured (e.g., bolted) to the chains <NUM> of the conveyor assembly <NUM> (<FIG>). As shown in <FIG>, <FIG>, and <FIG>, the bucket <NUM> is configured for receiving six articles C in a single layer in a 2x3 arrangement, but it is understood that the bucket <NUM> may be sized and shaped to hold articles of a different or same quantity in more than one layer and/or in different row/column arrangements (e.g., 1x6, 3x4, 2x6, 4x6, 3x8, 2x6x2, 3x4x2, 2x9, 3x6, etc.). In one example embodiment, as shown in <FIG> and <FIG>, the bucket <NUM> can receive a spacer insert <NUM> that can engage the translation plate <NUM>, as described in more detail below, so that the bucket <NUM> is configured to receive four articles in a 2x2 arrangement when the spacer insert <NUM> is included.

As shown in <FIG>, the sidewall <NUM> can extend upwardly from the base <NUM> on a downstream side of the bucket <NUM>. In one embodiment, the sidewall <NUM> can be secured (e.g., bolted) to the base <NUM>. In the illustrated embodiment, a wedge <NUM> can extend from the sidewall <NUM> (e.g., on a loading or article-receiving side of the bucket <NUM>) and can have a generally orthogonal downstream side <NUM>, a generally orthogonal upstream side <NUM>, and an oblique side <NUM> extending between the sides <NUM>, <NUM>. In one exemplary embodiment, the orthogonal sides <NUM>, <NUM> can extend transverse to the machine direction M. As shown in <FIG>, the wedge <NUM> is located on the sidewall <NUM> so that it is spaced from the base <NUM>. Accordingly, the wedge <NUM> can extend between guides of the article conveyor <NUM> and downstream guide rails as shown in <FIG> and <FIG> and as described in more detail below. Generally the wedge <NUM> can help engage articles C as they are loaded into the bucket <NUM> and guide the engaged articles C onto the base <NUM>.

In the illustrated embodiment, the translation plate <NUM> can be positioned on the base <NUM> and can be connected to the sidewall <NUM> by a hinge such as pivot arms <NUM>, which can include two pivot arms <NUM> at the tops of the translation plate <NUM> and the sidewall <NUM> (<FIG> and <FIG>) and a pivot arm <NUM> at the bases of the translation plate <NUM> and the sidewall <NUM> (<FIG> and <FIG>). In one embodiment, the translation plate <NUM> can be in the form of an L-shaped plate and can be movable in a depression <NUM> of the base <NUM>. In the illustrated embodiment, the translation plate <NUM> can include a first portion 125a that extends in a transverse direction that is perpendicular to the machine direction M and a second portion 125b that extends in the machine direction M (<FIG>). As shown in <FIG> and <FIG>, a cam follower <NUM> can be mounted to an extension <NUM> extending downwardly from the translation plate <NUM> through an opening or slot (not shown) in the base <NUM>. The cam follower <NUM> can be configured to interact with the actuating cam assembly <NUM> and the reset cam assembly <NUM> as described in more detail below. In the illustrated embodiment, the translation plate <NUM> can move (e.g., due to the interaction between the cam follower <NUM> and the actuating cam assembly <NUM>) on the pivot arms <NUM> from an initial configuration 142a (e.g., a loading configuration) to a secondary configuration 142b (e.g., a compacting configuration) (<FIG> and <FIG>). In the illustrated embodiment, the translation plate <NUM> can be retained in the loading configuration 142a against the sidewall <NUM> by the interaction between the cam follower <NUM> and the reset cam assembly <NUM> as described in more detail below or by any other suitable feature. In an alternative embodiment, the translation plate <NUM> can be biased toward the loading configuration 142a against the sidewall <NUM> by springs (e.g., associated with the pivot arms <NUM>) or any other suitable feature. In the compacting configuration 142b, the translation plate <NUM> can be moved away from the sidewall <NUM> (e.g., in the upstream direction) and toward the loading side of the bucket <NUM> (e.g., in the transverse direction) in order to compact the articles C in the bucket <NUM> as discussed in more detail below.

As shown in <FIG>, the translation plate <NUM> can include a slot or groove <NUM> that can be vertically oriented and that can receive a tongue <NUM> of the spacer insert <NUM> to help retain the spacer insert <NUM> against the translation plate <NUM>. The spacer insert <NUM> can further include a fastener that engages a bore <NUM> in the translation plate <NUM> for further securing the spacer insert <NUM> to the translation plate <NUM>. In one embodiment, the fastener can include a biased pin (not shown) that can be biased toward engagement with the bore <NUM> (<FIG>) by a spring (not shown) in the interior of the spacer insert <NUM>, and a locking pin <NUM> can be inserted into a bore (not shown) in the top of the spacer insert <NUM> to engage the bias pin and retain the bias pin in engagement with the bore <NUM>. Alternatively, a thumb screw or other suitable fastener can engage the bore <NUM> (e.g., an internally-threaded bore) and/or a bore in the base <NUM>. In one embodiment, the spacer insert <NUM> can be configured to take the space of one row of articles C, covering one of the fingers (e.g., finger 127a), so that the bucket <NUM> is configured for receiving the articles C in a 2x2 arrangement when the spacer insert <NUM> is used.

As shown in <FIG>, <FIG>, <FIG>, and <FIG>, each of the fingers 127a, 127b, 127c can be received in respective slots <NUM> in the base <NUM>. As shown in <FIG>, each of the fingers 127a, 127b, 127c can have a respective base arm 155a, 155b, 155c that is pivotably mounted to the base <NUM> at a pivot point <NUM> at an end of the base arm 155a, 155b, 155c. In one embodiment, the base arms 155a and 155c can pivot on an axle 160a at a downstream end of the base arms and the base arm 155b can pivot on an axle 160b at an upstream end of the base arm (<FIG>). As shown in <FIG>, each of the base arms 155a, 155b, 155c can include a downward protrusion <NUM> and a projection <NUM> for interacting with the cam assemblies <NUM>, <NUM> as described in more detail below. In the illustrated embodiment, the base arm 155a, 155b, 155c of each finger 127a, 127b, 127c can pivot about its pivot point <NUM> from an initial configuration (e.g., a retracted configuration), wherein the top end <NUM> of each finger 127a, 127b, 127c is disposed in the respective slot <NUM> below the support surface <NUM> of the base <NUM> (<FIG> and <FIG>), to a secondary configuration (e.g., an elevated configuration), wherein the top end <NUM> extends above the support surface <NUM> of the base <NUM> (<FIG>, <FIG> and <FIG>).

The buckets <NUM> could be otherwise shaped, positioned, arranged, and/or configured without departing from the disclosure.

As shown in <FIG>, the article conveyor <NUM> can include a belt conveyor or other suitable apparatus for moving the articles C toward the loading side of the buckets <NUM> in a plurality of lanes 163a, 163b, 163c. In one embodiment, the article conveyor <NUM> includes three lanes 163a, 163b, 163c for a bucket <NUM> configured to receive three rows of articles C (e.g., in a 2x3 arrangement). Accordingly, each lane 163a, 163b, 163c can provide one row of articles C. In an exemplary embodiment, one or more of the lanes can be deactivated (e.g., blocked) for buckets <NUM> configured to receive fewer rows of articles C. For example, the buckets <NUM> can include the spacer inserts <NUM> (<FIG>) so that they are configured to receive two rows of articles C (e.g., in a 2x2 arrangement) and one of the lanes 163a, 163b, 163c could be deactivated. Alternatively, the article conveyor <NUM> could be reconfigured or replaced to include only two lanes for loading articles C in a 2x2 arrangement when the spacer inserts <NUM> are included. In other embodiments, the article conveyor could include more than three lanes and/or each lane could provide more than one row of articles to each bucket.

In the illustrated embodiment, the articles C are arranged in each lane 163a, 163b, 163c to alternate between foil up and foil down orientations. Since the buckets <NUM> are sized to receive two articles C in each row in the exemplary embodiment, each lane 163a, 163b, 163c can supply two articles C so that one is foil up and one is foil down (<FIG>). In addition, each subsequent lane can be configured so that the orientations of the articles C are out of phase with the orientations of the articles of the prior, upstream lane. For example, the upstream lane 163a can load a foil down article C (the bottom B is visible in <FIG>) followed by a foil up article C (the top T is visible in <FIG>) for the first row, the next (intermediate) lane 163b can then load a foil up article C followed by a foil down article C for the second row, and the downstream lane 163c can then load a foil down article C followed by a foil up article C for the third row so that the articles C alternate between foil up and foil down orientations in each row and each column in each of the buckets <NUM>. Further, in the illustrated embodiment, each of the slots <NUM> and the respective fingers 127a, 127b, 127c is aligned with (e.g., for abutting) the bottom B of a respective foil up article C when the articles C are fully loaded in the buckets <NUM>. In an alternative embodiment, the fingers 127a, 127b, 127c could be aligned with foil down and/or foil up articles C.

In the illustrated embodiment, the article conveyor <NUM> includes a plurality of guides <NUM> that define the lanes (e.g., four guides <NUM> can define the three lanes 163a, 163b, 163c) and guide the articles C as they move along the lanes 163a, 163b, 163c. As shown in <FIG>, at least the downstream ends of each of the guides <NUM> can include an upper portion 167a spaced from a lower portion 167b to provide a clearance gap <NUM> so that the wedges <NUM> can pass between the portions 167a, 167b in the gap <NUM> as the buckets <NUM> move past the guides <NUM>. In one embodiment, the articles C can be moved on a conveyor belt (not shown) or any other suitable apparatus for moving the articles C along the guides <NUM> in the lanes 163a, 163b, 163c. As shown in <FIG> and <FIG>, a guide rail <NUM> can extend in the machine direction M from the article conveyor <NUM> for retaining the articles C in the buckets <NUM> as the buckets <NUM> move downstream from the article conveyor <NUM>. In the illustrated embodiment, an upstream end of the guide rail <NUM> extends from a downstream end of the downstream guide <NUM> of the downstream lane 163c. In one embodiment, the guide rail <NUM> can include an upper portion 173a, and a lower portion 173b spaced apart by a gap <NUM> for providing clearance for the wedges <NUM> (<FIG>). The article conveyor <NUM> and/or the guide rail <NUM> could be omitted or could be otherwise shaped, positioned, arranged, and/or configured without departing from the disclosure.

As shown in <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, the actuating cam assembly <NUM> is disposed on the cam base plate <NUM> proximate the downstream end <NUM> of the system <NUM> and is downstream from the article conveyor <NUM>. As shown in <FIG>, the actuating cam assembly <NUM> can include a plurality of actuating finger cam surfaces 177a, 177b, 177c for guiding the protrusions <NUM> of the respective fingers 127a, 127b, 127c from the retracted configuration to the elevated configuration (e.g., so that the tops <NUM> of the fingers 127a, 127b, 127c extend above the top surface <NUM> of the base <NUM>). For example, each of the finger cam surfaces 177a, 177b, 177c can include an upstream sloped surface portion <NUM> and a horizontal surface portion <NUM> extending downstream from the sloped surface portion <NUM>. The sloped surface portions <NUM> can gradually push the respective fingers 127a, 127b, 127c upwardly through the slots <NUM> by engaging the protrusions <NUM> and causing the base arms 155a, 155b, 155c to pivot about their pivot points <NUM>. In the illustrated embodiment, the protrusions <NUM> can slide along the horizontal surface portions <NUM> of the respective finger cam surfaces 177a, 177b, 177c to maintain the fingers 127a, 127b, 127c in the elevated configuration. As shown in <FIG> and <FIG>, the central cam surface 177b can be offset in the machine direction M from the outer cam surfaces 177a, 177c so that the protrusions <NUM> of the respective fingers 127a, 127b, 127c engage the respective cam surfaces 177a, 177b, 177c to be moved to the elevated configuration at substantially the same time even though the protrusion <NUM> of the central finger 127b is located downstream from the protrusions <NUM> the outer fingers 127a, 127c. In the illustrated embodiment, the protrusions <NUM> have rounded surfaces for sliding along the cam surfaces. However, a cam follower (not shown) or other suitable feature could be mounted to each of the protrusions for rolling or otherwise moving along the cam surfaces 177a, 177b, 177c.

As shown in <FIG> and <FIG>, the actuating cam assembly <NUM> can include a translating cam surface <NUM> for engaging the cam follower <NUM> of the translation plate <NUM>. In the illustrated embodiment, translating cam surface <NUM> can include a sloped surface portion <NUM> and a vertical surface portion <NUM> so that the cam follower <NUM> can engage the sloped surface portion <NUM> to gradually move the translation plate <NUM> via the extension <NUM> relative to the sidewall <NUM> and the base <NUM> on the pivot arms <NUM> to the compacting configuration 142b of the bucket <NUM>. In one embodiment, the cam follower <NUM> can roll along the vertical surface portion <NUM> to maintain the translation plate <NUM> in the compacting configuration 142b. As shown in <FIG> and <FIG>, the translating cam surface <NUM> can be offset in the machine direction M from the finger cam surfaces 177a, 177b, 177c so that the translation plate <NUM> is moved to the compacting configuration 142b after the fingers 127a, 127b, 127c are moved to the elevated configuration.

In the illustrated embodiment, the cam surfaces 177a, 177b, 177c, <NUM> extend along blocks that are mounted to the cam base plate <NUM>. As shown in <FIG> and <FIG>, the central finger cam surface 177b and the translating cam surface <NUM> are formed on the same block. The actuating cam assembly <NUM> could be otherwise shaped, positioned, arranged, and/or configured without departing from the disclosure. For example, any suitable number of cam surfaces could be formed on any suitable number of blocks. In another example, the one or more of the cam surfaces could be integrally formed with the cam base plate <NUM>.

As shown in <FIG>, the reset cam assembly <NUM> is mounted at an upstream end of the cam base plate <NUM> and includes a plurality of reset cam surfaces 197a, 197b, 197c for moving the respective fingers 127a, 127b, 127c to the retracted configuration (e.g., so that the tops <NUM> of the fingers 127a, 127b, 127c are moved down into the slots <NUM> and do not extend above the top surface <NUM> of the base <NUM>). In one embodiment, as a respective bucket <NUM> moves on the chains <NUM> from the underside of the conveyor assembly <NUM> along the upstream end <NUM> to move in the machine direction M on the upper side of the conveyor assembly <NUM>, the fingers 127a, 127b, 127c can move to the retracted configuration due to gravity. In the case that gravity is insufficient to move one or more of the fingers to the retracted configuration (e.g., due to friction), the reset cam surfaces 197a, 197b, 197c can engage the respective fingers 127a, 127b, 127c to move them to the retracted configuration. As shown in <FIG>, each of the reset cam surfaces 197a, 197b, 197c can include a sloped surface <NUM> that is angled downwardly from the upstream end <NUM> (e.g., each of the sloped surfaces <NUM> is angled so that its highest point is upstream from its lowest point). Accordingly the sloped surfaces <NUM> can engage the fingers 127a, 127b, 127c (e.g., at respective projections <NUM> extending from the protrusions <NUM> of the respective fingers) and can gradually push the projections <NUM> downwardly as the bucket <NUM> moves in the machine direction M. In one embodiment, the downward urging of the sloped surfaces <NUM> on the projections <NUM> (<FIG>) can cause the base arms 155a, 155b, 155c to pivot about their pivot points <NUM> and to move the tops <NUM> of the fingers downwardly into the slots <NUM>. In the case that the fingers 127a, 127b, 127c are configured with cam followers (not shown) (e.g., wherein the projections <NUM> can be axles for the cam followers in one embodiment), the cam followers can engage the cam surfaces <NUM> as the bucket <NUM> moves in the machine direction M.

As shown in <FIG>, the reset cam assembly <NUM> can include a transverse reset cam surface <NUM> for engaging the cam follower <NUM> of the translation plate <NUM> and moving the translation plate <NUM> to the loading configuration 142a of the bucket <NUM>. In the illustrated embodiment, the transverse reset cam surface <NUM> can include a sloped surface portion <NUM> and a vertical surface portion <NUM> so that the cam follower <NUM> can engage the sloped surface portion <NUM> to gradually move the translation plate <NUM> via the extension <NUM> relative to the sidewall <NUM> and the base <NUM> on the pivot arms <NUM> to the loading configuration 142a. In one embodiment, the cam follower <NUM> can roll along the vertical surface portion <NUM> to maintain the translation plate <NUM> in the loading configuration 142a. As shown in <FIG>, the transverse reset cam surface <NUM> can extend to a downstream end that is proximate to the upstream end of the translating cam surface <NUM> of the actuating cam assembly <NUM>. Accordingly, the transverse reset cam surface <NUM> can maintain the translation plate <NUM> in the loading configuration 142a via the cam follower <NUM> and the extension <NUM> until the translating cam surface <NUM> engages the cam follower <NUM> and moves the translation plate <NUM> to the compacting configuration 142b.

In the illustrated embodiment, the cam surfaces 197a, 197b, 197c, <NUM> extend along blocks that are mounted to the cam base plate <NUM>. As shown in <FIG>, the reset cam surfaces 197a, 197b are formed on the same block. The reset cam assembly <NUM> could be otherwise shaped, positioned, arranged, and/or configured without departing from the disclosure. For example, any suitable number of cam surfaces could be formed on any suitable number of blocks. In another example, the one or more of the cam surfaces could be integrally formed with the cam base plate <NUM>. In another example, the reset cam assembly <NUM> could be spaced downstream from the upstream end <NUM> and configured to move the fingers and the translation plate to the loading configuration 142a prior to or when the articles C are loaded into the buckets <NUM>. In an alternative embodiment, the reset cam assembly <NUM> could be omitted and the fingers 127a, 127b, 127c can be biased to the retracted configuration by springs or other suitable features and/or the translation plate <NUM> can be biased to the loading configuration by springs or other suitable features.

In the illustrated embodiment, the buckets <NUM> cooperate with one another to form an interior receiving space <NUM> that receives the articles C. As shown in <FIG>, <FIG>, <FIG>, and <FIG>, the receiving space <NUM> can be defined by the base <NUM> and the translation plate <NUM> of one bucket <NUM> and the sidewall <NUM> of an adjacent bucket <NUM> that is upstream from the receiving space <NUM>. As shown in <FIG> and <FIG>, the loading side of the buckets <NUM> can be at least partially closed by the guide rail <NUM> to further define the receiving space <NUM> as the buckets <NUM> move downstream from the article conveyor <NUM> after the articles C are loaded into the receiving space <NUM>. In one embodiment, each of the buckets <NUM> can include two bumpers <NUM> on the translation plate <NUM> (<FIG>) and two bumpers <NUM> on the downstream surface of the sidewall <NUM> (<FIG>, <FIG>, and <FIG>) so that the bumpers <NUM>, <NUM> extend into the receiving space <NUM>. Each of the bumpers <NUM>, <NUM> can be aligned with the fingers 127a, 127b, 127c so that the bumpers <NUM>, <NUM> can engage the foil up articles C in the receiving space <NUM>. The receiving spaces <NUM> could be otherwise shaped, positioned, arranged, and/or configured without departing from the disclosure. For example, the bumpers <NUM>, <NUM> could be configured to engage the foil up articles and/or the foil down articles.

In operation, the buckets <NUM> can move in the machine direction M from the upstream end <NUM> so that adjacent buckets <NUM> are proximate one another (e.g., closely spaced from one another as shown in <FIG>, <FIG>, and <FIG>) and/or abut one another and so that the translation plate <NUM> and the sidewall <NUM> of the adjacent buckets form the receiving spaces <NUM>. As shown in <FIG>, as the buckets <NUM> move downstream from the upstream end <NUM> and engage the reset cam assembly <NUM>, the projections <NUM> of the fingers 127a, 127b, 127c can engage the respective cam surfaces 197a, 197b, 197c to move the fingers 127a, 127b, 127c into the retracted configuration, and the cam follower <NUM> can engage the cam surface <NUM> to move the translation plate <NUM> to the loading configuration 142a. In one embodiment, with the fingers 127a, 127b, 127c in the retracted configuration, the translation plate <NUM> in the loading configuration 142a, and the buckets <NUM> positioned relative one another to form the receiving spaces <NUM>, the buckets <NUM> are prepared to receive the articles C. As shown in <FIG> and <FIG>, the wedge <NUM> of a bucket <NUM> can move into the lane 163a to engage a foil down article C at its oblique surface <NUM> and the side <NUM> of the wedge <NUM> of the next (upstream) bucket <NUM> can engage the foil up article C that is adjacent the first foil down article C in the lane 163a. As the buckets <NUM> continue to move in the machine direction, these two wedges <NUM> move through the gaps <NUM> of the guides <NUM> of the lane 163a so that the two articles C at the end of the first lane 163a are trapped between the wedges <NUM> to form the first row of articles C. The angled portion of one of the guides <NUM> can push the first row of articles C farther into the receiving space <NUM> as the buckets <NUM> move past the first lane 163a. In one embodiment, the articles C can slide over the slots <NUM> in the base <NUM> as they are pushed into the receiving space <NUM> with the fingers 127a, 127b, 127c in the retracted configuration.

In the illustrated embodiment, two articles C (e.g., a foil up article followed by a foil down article) at the end of the second lane 163b can be captured between the two wedges <NUM> as they move through the second lane 163b. The angled portion of the guide <NUM> at the downstream side of the lane 163b can push the articles C from the second lane 163b into the receiving space <NUM> as the buckets <NUM> move in the machine direction M to form the second row of articles C, and the second row can push the articles C in the first row farther into the receiving space <NUM>. Similarly, the wedges <NUM> can move through the third lane 163c to capture two end articles C (e.g., a foil down article followed by a foil up article) to form the third row of articles C. The angled portion of the final guide <NUM> can further push the articles C into the receiving space <NUM> to fully load the articles C into the receiving space <NUM>.

In the illustrated embodiment, the buckets <NUM> can move downstream from the article conveyor <NUM> so that the loading side of the buckets <NUM> is closed by the guide rail <NUM>. Accordingly, the guide rail <NUM> can cooperate with the translation plate <NUM> and the sidewall <NUM> to enclose the receiving space <NUM> with the wedges <NUM> moving through the gap <NUM> of the guide rail <NUM> (<FIG>). With the articles C loaded in the bucket <NUM>, the protrusions <NUM> of the fingers 127a, 127b, 127c can engage the respective cam surfaces 177a, 177b, 177c so that the protrusions <NUM> slide upwardly along the sloped surface portions <NUM> to the horizontal surface portions <NUM> to move the fingers 127a, 127b, 127c upwardly against their biases to the elevated configuration (e.g., as shown in <FIG> and <FIG>). Accordingly, the tops <NUM> of the fingers 127a, 127b, 127c move upwardly through the slots <NUM> to extend above the top surface <NUM> of the base <NUM>, thereby pushing upwardly on the bottoms of the foil up articles C. As shown in <FIG>, the foil up articles are then elevated with respect to the foil down articles C, which remain in contact with the base <NUM>.

Accordingly, as shown in <FIG>, the rims R of the elevated foil up articles C are spaced above the bottoms B of the foil down articles, and the rims R of the foil down articles C are spaced below the bottoms B of the elevated foil up articles C. In addition, the sloped sides S of the adjacent articles C can allow narrower portions of the articles to be aligned. As the buckets <NUM> continue to move in the machine direction M, the cam follower <NUM> can move past the downstream end of the transverse reset cam surface <NUM>, which was retaining the translation plate <NUM> in the loading configuration 142a, and can engage the sloped portion <NUM> of the translating cam surface <NUM> to move the cam follower <NUM> in the transverse direction that is transverse to the machine direction M to the vertical surface portion <NUM> of the translating cam surface <NUM>. This movement of the cam follower <NUM> can move the translation plate <NUM> via the extension <NUM> from the loading configuration 142a to the compacting configuration 142b, wherein the translation plate <NUM> moves on the pivot arms <NUM> away from the sidewall <NUM> to which it is connected. In one embodiment, the translation plate <NUM> can move on the pivot arms <NUM> toward the guide rail <NUM> and the sidewall <NUM> of the upstream bucket <NUM> (e.g., diagonally into the receiving space <NUM>). This movement of the translation plate <NUM> can compact the arrangement of the articles C between the translation plate <NUM> of the bucket <NUM>, the guide rail <NUM>, and the sidewall <NUM> of the upstream bucket <NUM>. The articles C can then engage one another at the sloped sides as shown in <FIG>, limiting or removing any slack or freedom of movement between the arranged articles C. The protrusions <NUM> and the cam follower <NUM> can continue to move along the cam surfaces 177a, 177b, 177c, <NUM> to retain the arrangement of the articles C in the compacted configuration as the buckets <NUM> move in the machine direction M and are in engagement with the cam assembly <NUM>.

In one embodiment, a robot arm or other suitable apparatus (not shown) can engage the articles C (e.g., by vacuum cups or other suitable apparatus via open tops of the buckets <NUM>) while they are in the compacted configuration and remove the articles from the interior space <NUM> to be loaded into a carton (not shown). Subsequently, the bucket <NUM> can move to the downstream end <NUM> and the cam follower <NUM> and the protrusions <NUM> of the fingers 127a, 127b, 127c can move past the downstream ends of the cam surfaces <NUM>, 177a, 177b, 177c. The bucket <NUM> can be returned to the upstream end <NUM> by the conveyor to continue the loading and compacting of the articles C. The articles C could be otherwise loaded and/or compacted without departing from the disclosure.

In one embodiment, the compacting of the articles C in the 2x3 arrangement can allow the arrangement to be more reliably acquired by the robot arm since there is less room for the articles C to move relative to one another in the arrangement when the articles are compacted. Accordingly, the locations of the articles C are more predictable in the interior space when the arrangement is compacted to limit or remove freedom of movement of the articles relative to one another. Additionally, in one embodiment, the carton into which the articles C are ultimately loaded by the robot arm is configured for holding the articles C in the uncompacted arrangement (e.g., wherein none of the articles is elevated with respect to the other articles) and has an opening that is wider than the footprint of the compacted arrangement of articles C as acquired from the interior space <NUM> by the robot arm. The compacted arrangement then can more easily fit through the opening and be inserted into the carton than an uncompacted arrangement since the compacted articles are less likely to catch on an edge of the carton as they are loaded into it. After the articles are loaded into the carton, the robot arm can disengage from the articles and the articles can settle in the carton into an uncompacted arrangement in one embodiment.

<FIG> are schematic perspective views of a bucket <NUM> and two interior spaces 390a, 390b according to a second embodiment of the disclosure. The second embodiment is generally similar to the first embodiment, except for variations noted and variations that will be apparent to one of ordinary skill in the art. Accordingly, similar or identical features of the embodiments have been given like or similar reference numbers. The bucket <NUM> can be for use in the system <NUM> or in a similar system. As shown in <FIG>, the bucket <NUM> can be similar to the buckets <NUM> of the first embodiment except that the bucket <NUM> is configured for receiving the articles C in two separate <NUM>×<NUM> arrangements in the two receiving spaces 390a, 390b. For example, the bucket <NUM> can be configured to be wider than the buckets <NUM> of the first embodiment in the direction that is transverse to the machine direction so that each of the interior spaces 390a, 390b of the bucket <NUM> is configured to receive two foil up articles C alternating with two foil down articles C in a single column (e.g., in four rows having one article C each). In one embodiment, the foil up articles C in the receiving space 390b are aligned with the slots <NUM> for engaging the fingers 127a, 127c. The finger 127b can be omitted and/or deactivated in one embodiment (e.g., the cam surface 177b could be omitted). In an exemplary embodiment, the foil up articles C in the receiving space 390a could be aligned with slots (not shown) for engaging additional figures (not shown). In one embodiment, the foil up articles in the receiving space 390a can be aligned with the foil down articles in the receiving space 390b and the foil down articles in the receiving space 390a can be aligned with the foil up articles in the receiving space 390b. Alternatively, the foil up articles and the foil down articles in the receiving space 390a could be aligned with the respective foil up article and foil down articles in the receiving space 390b.

As shown in <FIG>, the sidewall <NUM> is omitted in the bucket <NUM> and the translation plate <NUM> includes a first portion 325a extending transverse to the machine direction M, a second portion 325b extending in the machine direction M from an end of the first portion 325a, and a third portion 325c extending from the second portion 325b in the transverse direction (e.g., parallel to the first portion 325a). In one embodiment, the first portion 325a and the third portion 325c can cooperate to at least partially form the first receiving space 390a. The third portion 390a further can cooperate with the first portion 325a of the translation plate <NUM> of an adjacent upstream bucket <NUM> to at least partially form the second receiving space 390b. An extension and cam follower (not shown) that are similar or identical to the extension <NUM> and cam follower <NUM> of the first embodiment can extend from the translation plate <NUM> through the base <NUM>. The extension and the cam follower can be constrained to move (e.g., due to interaction with the cam surface <NUM>) in the transverse direction since the translation plate <NUM> is not hinged to a sidewall (e.g., does not need to pivot on a hinge) and since the arrangement of articles includes only one column and the articles are compacted in only the transverse direction. As shown in <FIG>, the wedges <NUM> can extend from each of the portions 325a, 325c of the translation plate <NUM> and can operate similarly to the wedges <NUM> of the first embodiment.

In the second embodiment, the articles C can be loaded into the interior spaces 390a, 390b in a similar manner as in the first embodiment and the foil up articles C can be elevated relative to the foil down articles C by respective fingers in a similar manner as in the first embodiment. In one embodiment, when the bucket <NUM> moves along the guide rail <NUM>, the translation plate <NUM> can be moved only in the direction transverse to the machine direction M when the cam follower engages the translating cam surface <NUM>. Accordingly, the translation plate <NUM> can compact the articles C in the <NUM>×<NUM> configuration in the direction transverse to the machine direction. The bucket <NUM> and/or the interior spaces 390a, 390b could be omitted or could be otherwise shaped, positioned, arranged, and/or configured without departing from the disclosure.

Claim 1:
A method of arranging articles (C), the method comprising:
moving a bucket (<NUM>, <NUM>) in a machine direction (M) on a conveyor assembly (<NUM>), the bucket (<NUM>, <NUM>) comprising a translation plate (<NUM>, <NUM>), at least a finger (127a, 127b, 127c), and a receiving space (<NUM>, 390a, 390b);
loading a plurality of articles (C) into an arrangement of articles (C) in the receiving space (<NUM>, 390a, 390b) as the bucket (<NUM>, <NUM>) moves in the machine direction (M), the arrangement of articles (C) comprising at least a first article (C) and a second article (C) of the plurality of articles (C);
elevating at least the first article (C) with respect to the second article (C) in the receiving space (<NUM>, 390a, 390b) of the bucket (<NUM>, <NUM>) with the finger (127a, 127b, 127c); and
compacting the arrangement of articles (C) in the bucket (<NUM>, <NUM>) with the translation plate (<NUM>, <NUM>).