Patent Document

PRIORITY 
     This application claims priority to U.S. Provisional Patent Application Ser. No. 61/817,895, filed May 1, 2013, entitled “Device for Stabilizing a Pallet,” the disclosure of which is incorporated by reference herein. 
    
    
     BACKGROUND 
     The present disclosure relates generally to palletizing and palletizing loads for transit and is more particularly directed to a device that applies a load stabilizer to articles, containers, or cartons that are stacked onto a pallet for transit. The innovation will be disclosed in connection with, but not necessarily limited to, a device that applies a load stabilizer onto potential shift points of a palletized load and more particularly to a device that places an adhesive load stabilizer at potential shift points of the palletized load. 
     When articles are stacked one on top of the other, the higher the stack, the greater the tendency for the stack to fall over when subjected to a disturbance such as a transit or shipping load. When layers of articles are stacked on a pallet to create a palletized load for transit, the load has better stability due to contact between adjacent articles, but the load still suffers from height instability issues and the articles positioned on the outside columns can fall outwards unless stabilized. 
     When articles are palletized for transit in a commercially available palletizing machine, the palletized loading process can encounter the same column height and outside column stability issues. Previous solutions have included placing layer sized sheets of cardboard between layers, but these require large feeding and placement mechanisms in areas that compete for space, and require costly cardboard sheets. 
     Thus, there is a need for devices and methods to conveniently stabilize palletized loads with smaller mechanisms that eliminate the need for large and costly feeding and placement mechanisms. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings illustrate embodiments, and, together with the specification, including the detailed description which follows, serve to explain the principles of the present innovation. 
         FIG. 1  is a partial cross sectional view of an example automatic palletizer. 
         FIG. 2  is a fragmentary isometric view of at least one load stabilizer of the automatic palletizer of  FIG. 1  mounted on a release liner. 
         FIG. 3  is a partial cross sectional view of a load stabilizer applier of the automatic palletizer of  FIG. 1 . 
         FIG. 4  is a top view of a palletized load shown in  FIG. 1 . 
         FIG. 5  is an isometric view of the palletized load shown in  FIG. 1 . 
         FIG. 6  is an isometric view of an upper level of the automatic palletizer of  FIG. 1  showing a plurality of articles placed and aligned on top of a pair of doors. 
         FIG. 7  is an isometric view of the automatic palletizer of  FIG. 1  showing the doors opening to drop the central portion of articles onto a palletized load. 
         FIG. 8  is an isometric view of the automatic palletizer of  FIG. 1  showing the doors in an open position to drop the outer portion of articles onto the palletized load. 
         FIG. 9  is an isometric view of the automatic palletizer of  FIG. 1  showing the palletized load lowered below the doors. 
         FIG. 10  is an isometric view of the automatic palletizer of  FIG. 1  showing the doors in a closed position over the palletized load. 
         FIG. 11  is a fragmentary isometric view of the automatic palletizer of  FIG. 1  showing the palletized load being wrapped. 
         FIG. 12  is a partial cross sectional view of another example automatic palletizer. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, like reference characters designate like or corresponding parts throughout the several views. Also, in the following description, it is to be understood that terms such as front, back, inside, outside, and the like are words of convenience and are not to be construed as limiting terms. Terminology used in this patent is not meant to be limiting insofar as devices described herein, or portions thereof, may be attached or utilized in other orientations. 
     It should be appreciated that any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. 
       FIG. 1  shows a partial cross sectional view of automatic palletizer  200 , such as the Alvey® 910 palletizer sold by Intelligrated located at 7901 Innovation Way, Mason, Ohio 45040. Palletizer  200  of the present example is a multi-story unit comprising upper level  202  for receiving and aligning a plurality of articles  40  and lower level  204  for discharging articles  40  as palletized load  20  via discharge conveyor  206 . A feed conveyor not shown feeds individual articles  40  into upper level  202  of palletizer  200  for palletizing. Palletizer  200  comprises elevator  208  movable within elevator shaft  210 . Elevator  208  is driven within elevator shaft  210  by elevator drive not shown that can be chain or hydraulic driven. In the present example, elevator  208  is centrally located within elevator shaft  210  and is configured to move vertically within elevator shaft  210 . In other versions, elevator  208  is offset within elevator shaft  210 . In still other versions, elevator  208  moves in other suitable directions e.g., horizontally, obliquely, etc. within elevator shaft  210 . Still other suitable configurations for elevator  208  and/or elevator shaft  210  will be apparent to one with ordinary skill in the art in view of the teachings herein. 
     Elevator  208  is configured to receive pallet  28  and to move up and down as sequential layers of articles  40  are discharged from upper level  202  and stacked on top of pallet  28  to create palletized load  20 . As shown in  FIG. 1 , upper level  202  is separated from lower level  204  by a pair of movable doors  214 . In the present example, doors  214  are positioned at a top portion of elevator shaft  210 . Doors  214  are nominally positioned in a closed position not shown to receive a layer of articles  40  thereon (see  FIG. 6 ). Once a layer of articles  40  is positioned on doors  214 , doors translate outwardly to an open position, as shown in  FIGS. 1 and 8 , to discharge the layer of aligned articles  40  onto an empty pallet  28  or palletized load  20  located beneath doors  214 . 
     Wrap ring  216  is positioned within lower level  204  and is motor driven to rotate about elevator shaft  210 . Wrap ring  216  is shown sectioned and includes a roll of pallet wrap  218 . Accordingly, when actuated, wrap ring  216  is configured to wrap palletized load  20  by rotating around palletized load  20  as palletized load  20  is moved up and down in elevator shaft  210 . Wrap ring  216  thereby wraps the sides of palletized load  20  with pallet wrap  218  to stabilize the outer columns of palletized load  20 . While wrap ring  216  of the present example includes a circular configuration, other suitable configurations for wrap ring  216  will be apparent to one with ordinary skill in the art in view of the teachings herein. 
     Upper level  202  of automatic palletizer  200  further comprises stabilizer appliers  50  supported by framework  212  of automatic palletizer  200  and positioned above palletized load  20  to place at least one adhesive load stabilizer  100  onto a top surface of palletized load  20 . Load stabilizers  100  thereby hold articles  40  of palletized load  20  together to thereby decrease stability issues within palletized load  20 . Stabilizer appliers  50  can place load stabilizers  100  on the uppermost layer of articles  40  on palletized load  20 , or stabilizer appliers  50  can place load stabilizers  100  on top of each layer of articles  40  within palletized load  20 . Alternatively, stabilizer appliers  50  can place load stabilizers  100  on a side surface of articles  40  of palletized load  20 . This can be in addition to or instead of using pallet wrap  218 . Still other suitable configurations for stabilizer appliers  50  and/or load stabilizers will be apparent to one with ordinary skill in the art in view of the teachings herein. 
       FIG. 2  is a fragmentary isometric view of load stabilizer  100  used to secure palletized load  20  for transit. Load stabilizers  100  are operably configured to remain secured to palletized load  20  during transit, yet allow articles  40  on palletized load  20  to be easily separated when depalletized. As shown in  FIG. 2 , load stabilizer  100  comprises stabilizer sheet  102  and adhesive layer  104  attached thereto. Stabilizer sheet  102  is non-adhesive. In some versions, stabilizer sheet  102  is a tearable or frangible material, such as paper. In other versions, stabilizer sheet  102  is formed from Tyvek, plastic film, fibrous material, foam, elastomerics, or other suitable materials. Stabilizer sheet  102  can be cut, perforated, or scored to provide lines of easy tearing in certain directions such as those found during depalletizing. Adhesive layer  104  comprises a releasable adhesive such as the low tack adhesive used on Post-It® Notes. Load stabilizers  100  can be opaque, transparent, or translucent. 
     Adhesive layer  104  of load stabilizer  100  is positioned on release liner  105 . The portion of release liner  105  coupled to adhesive layer  104  is formed from a wax or other slick material to provide protection of adhesive layer  104  until release liner  105  is removed prior to the application of load stabilizer  100  to palletized load  20 .  FIG. 2  shows release liner  105  as elongated strip  106  to receive a plurality of load stabilizers  100 . Alternatively, release liner  105  can be individual sheets applied to a single load stabilizer  100 . In the present example, load stabilizers  100  are spaced equally along the length of elongated strip  106  of release liner  105  for sequential feeding and release of a plurality of load stabilizers  100 . Release liner  105  is perforated with rows of equally spaced holes  107  to engage drive pins not shown within stabilizer applier  50  for driving and control of release liner  105 . Still other suitable configurations for load stabilizers will be apparent to one with ordinary skill in the art in view of the teachings herein. 
       FIG. 3  shows a partial cross section of stabilizer applier assembly  50 .  FIG. 3  illustrates stabilizer applier assembly  50  as a motorized system that uses the above described elongated strip  106  configuration of release liner  105  to store and dispense load stabilizers  100 . Stabilizer applier assembly  50  includes feeder configured to feed load stabilizers  100  to stabilizer applier  55 . Arrows are provided to show the feed path of elongated strip  106  of release liner  105  and load stabilizers  100  through feeder  51 . In the present example, feeder  51  comprises feed roll  52 , idler pulley  53 , peel bar  54 , liner guide  57 , and drive pulley  58  positioned within exterior case  50   a . Feed roll  52  is rotatably attached to exterior case  50   a  and is configured to store a wrapped roll of elongated strip  106  of release liner  105  with load stabilizers  100 . Elongated strip  106  is fed from feed roll  52  to wrap around idler pulley  53 , which is rotatably attached to exterior case  50   a . Idler pulley  53  is positioned below feed roll  52 . Idler pulley  53  is configured to contact and rotate with load stabilizer  100  side of elongated strip  106 . Elongated strip  106  is then fed to peel bar  54 , which is fixed to exterior case  50   a . Elongated strip  106  passes along a top surface of peel bar  54  and then bends 180 degrees around end  54   a  of peel bar  54 . As elongated strip  106  bends around peel bar  54 , the stiffer load stabilizer  100  peels away from elongated strip  106 . When elongated strip  106  of release liner  105  pulls farther around peel bar  54 , more of load stabilizer  100  peels from liner  105  and hangs in the air, as shown in  FIG. 3 . 
     Stabilizer applier  55  is configured to receive load stabilizer  100  from feeder  51 . Stabilizer applier  55  is disposed adjacent to peel bar  54  and comprises a vacuum pad  56  to receive the peeled load stabilizer  100 . With vacuum applied to vacuum pad  56 , load stabilizer  100  is held against vacuum pad  56 . In the present example, stabilizer applier  55  is movable to extend outwardly through opening  59  of exterior case  50   a  to place load stabilizer  100  against palletized load  20 . Stabilizer applier  55  is then retracted back within exterior case  50   a  to receive the next load stabilizer  100 . Stabilizer applier  55  is reciprocated up and down by a motor (not shown). Other suitable configurations for operating stabilizer applier  55  will be apparent to one with ordinary skill in the art in view of the teachings herein. 
     Once load stabilizer  100  is peeled from elongated strip  106 , elongated strip  106  passes around liner guide  57  and wraps around drive pulley  58 . Accordingly, idler pulley  53  and liner guide  57  are positioned adjacent peel bar  54  to maintain the alignment of elongated strip  106  relative to peel bar  54 . Drive pulley  58  is rotatably driven by a motor (not shown) to wrap elongated strip  106  around drive pulley  58 . Drive pulley  58  includes a release liner engagement feature such as slot  58   a  that is configured to engage with and pull on a free end of release liner  105  as drive pulley  58  rotates. Accordingly, drive pulley  58  rotates to thereby rotate liner guide  57 , idler pulley  53 , and feed roll  52  to pull elongated strip  106  from feed roll  52  to drive pulley  58 . Drive pulley  58  thereby wraps the empty elongated strip  106  onto drive pulley  58 .  FIG. 3  shows drive pulley  58  rotating in a clockwise direction, driven by a drive motor (not shown) located on a back side of the case  50   a . Other configurations for stabilizer applier  50  will be apparent to one with ordinary skill in the art in view of the teachings herein. 
       FIG. 4  is a top view of palletized load  20  showing top surface  26  of palletized load  20 . Palletized load  20  includes a plurality of contact lines  27   a ,  27   b ,  27   c  where two or more adjacent articles  40  contact each other. Articles  40  contact at each of contact lines  27   a ,  27   b ,  27   c , and in this example, cross at intersection points  42   a ,  42   b . Each one of contact lines  27   a ,  27   b ,  27   c  and intersection points  42   a ,  42   b  represent potential shift points that can allow articles  40  to separate or shift away from adjacent articles  40  of palletized load  20  under transit. This can destabilize palletized load  20 . 
       FIG. 5  is an isometric view of palletized load  20 , which comprises layers  22 ,  24 ,  26  of articles  40  stacked on top of pallet  28 . Articles  40  of the present example are placed three wide and two long on each layer  22 ,  24 ,  26 . Of course, other suitable combinations for layers  22 ,  24 ,  26  will be apparent to one with ordinary skill in the art in view of the teachings herein. Once a predetermined number of layers  22 ,  24 ,  26  of articles  40  have been received on palletized load  20 , stabilizer appliers  50  place load stabilizers  100  to one or more potential shift points of articles  40  of palletized load  20  to provide transit stability. For example, as shown in  FIG. 5 , a first stabilizer applier  50  is positioned above uppermost layer  26  of palletized load  20  and a second stabilizer applier  50  is shown with stabilizer applier  55  extended along axis Z-Z to apply load stabilizer  100  onto palletized load  20 . While  FIG. 5  shows two stabilizer appliers  50 , any suitable number of stabilizer appliers  50  can be used to apply any suitable number of load stabilizers  100 .  FIG. 5  further shows that load stabilizer  100  is sized to cover a portion of the top surface of palletized load  20 . In other versions, load stabilizer  100  is sized to cover an entire surface of palletized load  20 . 
       FIGS. 1, 6, 7, 8, and 9  will now be referred to describe the operation of automatic palletizer  200 . Turning to  FIG. 6 , an isometric view of upper level  202  of automatic palletizer  200  is shown with a plurality of articles  40  placed and aligned on top of doors  214 . While the number of articles  40  on a layer differs from  FIGS. 1-5 , the operation of automatic palletizer  200  is the same. Turning to  FIG. 7 , doors  214  over elevator shaft  210  ( FIG. 1 ) are opened a sufficient amount to drop the central portion of articles  40  on top of palletized load  20  located just beneath doors  214 . In  FIG. 8 , doors  214  are fully opened and the remaining articles  40  have dropped on top of palletized load  20 . In this position, articles  40  are stabilized on top of palletized load  20 . With palletized load  20  paused in this position, one or more of stabilizer appliers  50  are actuated to place load stabilizers  100  ( FIG. 1 ) onto palletized load  20  (see  FIG. 5 ) while upper articles  40  are in upper level  202  of automatic palletizer  200 . 
     Turning to  FIG. 9 , palletized load  20  is dropped below doors  214  and into lower level  204  ( FIG. 1 ) of automatic palletizer  200  and elevator  208  ( FIG. 11 ) is paused. In another embodiment, load stabilizers  100  ( FIG. 1 ) can be dropped down from upper level  202  to extend at least partly into lower level  204  ( FIG. 1 ) to apply load stabilizers  100  ( FIG. 1 ) onto palletized load  20 . Doors  214  are then closed to receive another pallet  28  ( FIG. 1 ) and/or layer of articles  40  ( FIG. 9 ), as shown in  FIG. 10 . 
       FIG. 11  is a fragmentary isometric view of palletized load  20  being wrapped by wrap ring  216 . While palletized bags are shown, any article  40  may be palletized. Once the desired amount of articles  40  and load stabilizers  100  ( FIG. 1 ) are placed on palletized load  20 , elevator  218  moves downward as pallet wrap  208  is rotatably wrapped around palletized load  20  by wrap ring  216 . Once palletized load  20  is wrapped, elevator  208  moves downward to align and move the stabilized palletized load  20  onto discharge conveyor  206  ( FIG. 1 ). Automatic palletizer  200  then repeats the process as many times as is necessary to palletize a delivery for transit. 
     Another example automatic palletizer  300  is shown in  FIG. 12 . Automatic palletizer  300  is similar to automatic palletizer  200  ( FIG. 1 ) in that automatic palletizer  300  comprises an upper level  302  and a lower level  304  separated by movable doors  314 . Lower level  304  is similar to lower level  204  ( FIG. 1 ) and is configured to discharge articles  40  as palletized load  20  via discharge conveyor  206 . Upper level  302  is similar to upper level  202  and is configured to receive and align a plurality of articles  40 . Accordingly, articles  40  are positioned on pallet  28  on elevator  308  within elevator shaft  310 , load stabilizers  100  ( FIG. 1 ) are applied by stabilizer applier assemblies  350 , and palletized load  20  is wrapped with pallet wrap  318  by wrap ring  316 . Stabilizer applier assemblies  350  are similar to stabilizer appliers  50 . Alternatively, stabilizer applier assemblies  350  are mounted to a side surface of automatic palletizer  300  instead of framework  312 . 
     Stabilizer applier assemblies  350  are positioned within lower level  304  and extend laterally within elevator shaft  310  to apply load stabilizers  100  to palletized load  20 . As shown in  FIG. 12 , stabilizer applier assemblies  350  are coupled with a side surface of elevator shaft  310  by extendable arms  352 . When extendable arms  352  are in a retracted position, stabilizer applier assemblies  350  are retracted within elevator shaft  310  such that elevator  308  is free to move past stabilizer applier assemblies  350 . When extendable arms  352  are in an extended position, as shown in  FIG. 12 , stabilizer applier assemblies  350  are positioned above palletized load  20  such that stabilizer applier assemblies  350  are able to apply load stabilizers  100  to a top surface of palletized load  20  as described above. Other suitable configurations for automatic palletizer  300  will be apparent to one with ordinary skill in the art in view of the teachings herein. 
     The foregoing description of an embodiment has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described in order to best illustrate the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Although only a limited number of embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its scope to the details of construction and arrangement of components set forth in the preceding description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, specific terminology had been used for the sake of clarity. It is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. It is intended that the scope of this provisional filing will be better defined by the claims submitted with a later non-provisional filing.

Technology Category: 7