FLEXIBLE MULTI-PACKING SYSTEM
Technical Field
The present invention relates generally to packaging systems and more particularly relates to a flexible packaging system for the creation of unique or unusual multi-packs of beverage cans and bottles
Background of the Invention
Conveyor-type packaging lines are well known in the packaging industry High-speed packaging lines are used to pack large volumes of beverage cans and bottles within containers of various configurations These packaging lines generally include a driven conveyor of some type The cans or bottles may be placed on the conveyor and then dπven to a loading point where they are inserted by various means into the container The most common type of container is the well-known multi-pack (six pack or twelve-pack) of cans or bottles The container is generally made from paperboard or similar materials After loading, the container is sealed and shipped to a retail outlet lor sale to the consumer By way of example, The Mead Corporation of Dayton, Ohio and Riverwood
International Corporation oi Atlanta, Georgia both manufacture vaπous types of high-speed multi-packing equipment
These known types of high-speed packaging lines are well equipped to process high volumes of cans or bottles into multi-packs m a uniform fashion These known lines, however, are not particularly well adapted to the processing of low volumes, "specialty" multi-packs, or uniquely configured containers Rather, the known packaging lines are generally designed for the high speed processing of a specific type of can or bottle with a specific type of container Adapting an existing packaging line for a limited production run is often time intensive and may result in unacceptable conversion or down time of the packaging equipment Further, it may not be efficient or cost effective to dedicate a high-speed line to a lower volume or a lower speed product or production run
What is needed, therefore, is a multi-packing system that can accommodate quickly unique configurations of containers or accommodate lower volume production without unnecessary down time, conversion time, or costly changeovers Such a multi-packmg system must be easily adaptable to different
configurations of containers and products without unduly limiting the overall production capacity.
Summary of the Invention The present invention thus provides a flexible multi-packing system for use with a first conveyor system having a number of products loaded in an orientation such as rows. The system includes a diverter positioned across one of the rows and a second conveyor system positioned in proximity to the first conveyor system. The second conveyor system includes a number of containers thereon. The flexible multi-packing system also includes a pathway extending from the diverter to the second conveyor system, such that the diverter diverts the products on one of the rows to the containers on the second conveyor system via the pathway.
Specific embodiments of the present invention include the diverter being in the form of a twister. The twister may be a curved structure such that the products are rotated from a vertical orientation to a horizontal orientation. The twister may be made from metal, plastic, or any similar material. The pathway may be a rail or any substantially rigid material. The pathway also may be a belt. Any number of the diverters and the pathways may be used. The container may include six, seven, twelve, or any number of the products therein. The container may have any number of side panels and may be in the shape of a triangle, a rectangle, an octagon, or any other shape.
The second conveyor system may be positioned lower than the first conveyor system. The pathway may include an incline extending from the first conveyor system to the second conveyor system such that the products travel along the pathway by the force of gravity. The second conveyor system may include a belt or a number of supports. The supports may be spaced apart by a predetermined distance such that the containers are positioned between each pair of the supports. The flexible multi -packing system also may include a rail system in communication with the pathway. The rail system may include a number of rails positioned adjacent to each other such that each of the rails leads to the second conveyor system or to a lane of another type of packaging equipment. Each of the rails concurrently fills a lane within the containers. A "lane" may signify a row, a column, or other type of array within the container. Each of the rails may have a length accommodating or corresponding to the number of products intended to be filled by the rail into the corresponding lane of the
container. The rail syste m also may include one or more stoppers positioned at various locations therein.
The flexible multi-packing system also may include a first distribution system. The first distribution system may include an expanding pathway having a number of lanes. The lanes may include a divider positioned therein. The first distribution system also may include a second diverter in communication with the expanding pathway. The second diverter may rotate the products from the horizontal orientation back to the vertical orientation. The second diverter may lead to a number of tubes. The products may travel through the tubes to the containers on the second conveyor system. The first distribution system also may include a number of stoppers. The flexible multi-packing system may have a number of the distribution systems.
The method of the present invention provides for the creation of multi-packs of products from a high-speed conveyor system. The high-speed conveyor system has a number of products organized in a vertical fashion in a number of rows. The method includes the steps of attaching a gravity feed distribution system to one of the rows, rotating the products on the row from the vertical orientation to a horizontal orientation, feeding the products along the gravity feed distribution system by rolling or sliding, and loading the products into a container. Two or more gravity feed systems may be used. The gravity feed distribution system may have a number of rails such that the feed step includes feeding the products along the rails and then loading the products into a container from the rails. One or more rails may be blocked by a stopper. A second rotating step may be used after the feeding step. A multi-pack created by this method may have a multi-sided shape, such as a triangular, rectangular, or hexagonal shape.
Brief Description of the Drawings
Fig. 1 is a perspective view of a multi-packing system of the present invention with one twister and one rail leading to an alternative conveyor.
Fig. 2 is a perspective view of a multi-packing system with two twisters and two rails.
Fig. 3 is a perspective view of a multi-packing system with one twister and one rail leading to an alternative conveyor loaded with triangular containers.
Fig 4 is a perspective view of a multi-packmg system with two twisters and two rails leading to an alternative conveyor loaded with triangular containers
Fig 5 is a perspective view of a multi-packmg system with one twister leading to multiple rails with a stopper
Fig 6 is a perspective view of a multi-packmg system with two twisters leading to multiple rails and stoppers
Fig 7 is a perspective view of a multi-pack g system with a number of twisters each leading to a distribution system having expanding rails, a divider, a second twister, and a number of tubes
Fig 8 is a perspective view of the multipacking system of Fig 7 with the use of a number of stoppers
Pig 9A is a perspective view ot the configuration ot a number ot tubes used to fill a twelve pack Fig 9B is a perspective view of the configuration of a number of tubes used to fill two six packs
Fig 9C is a perspective view of the configuration of a number of tubes used to fill a seven pack
Fig 9D is a perspective view of the configuration of a number of tubes used to fill two seven packs
Fig 9E is a perspective view of the configuration of a number of tubes used to fill a triangular six-pack
Detailed Description of the Invention Referring now in more detail to the drawings, in which like numerals refer to like parts throughout the several views, Fig 1 shows a conveyor system 100 of the present lm ention The conveyor system 100 may include a conveyor belt 110 that is driven and controlled in a conventional mannei I he conveyor belt 110 may be a conventional flexible belt, a senes of rollers, or any conventional type of device intended for movement along a substantially horizontal plane The conveyor system 100 and the conveyor belt 110 may be any type of conveyor device commonly used in the packaging industry
The conveyor system 100 may have a number oi products 120 positioned on the conveyor belt 110 The products 120 may be conventional cans or bottles or similar types of
erage containers Specifically the products 120 may be plastic bottles The pioducts 120 also may be any type of object commonly used on a packaging line and may have shapes other than round or
cylindrical. Any number of products 120 may be used. The products 120 as shown herein are generally transported in an upright or vertical orientation. The products 120 are generally organized in a series of rows 130 on the conveyor belt 120. The rows 130 may extend in any direction. In Fig. 1 , five rows 130 are shown, a first row 131, a second row 132, a third row 133, a fourth row 134, and a fifth row 135. Any number of rows 130 of products 120, however, may be used.
The conveyor system 100 may include a twister 140 and a rail 150 so as to divert some or all of the products 120 on one or more of the rows 130 away from the conveyor belt 110. As is shown, the twister 140 may be a curved structure than contacts the products 120 in the first row 131 or any other row 130.
After the initial contact, the momentum of the products 120 and the shape of the twister 140 may force the products 120 from their vertical orientation on the conveyor belt 110 to a horizontal and rolling orientation on the rail 150. The twister 140 may be fixedly attached to the conveyor belt 110 or the twister 140 may be removably attached via locking sections, snap fit, or any other conventional type of attachment means. The twister 140 may be any type of curved structure that twists the products 120 to a horizontal orientation. The twister 140 may be made of a rigid material or a flexible material. For example, the twister 140 may be made from metal, plastic, or other types of similar materials. Alternatively, the twister 140 may actually grab each product 120 and orient it horizontally upon the rail 150 by means of, for example, a mechanical arm. Any other type of diversion means also may be used, such as magnetics, a vacuum, or similar forces.
If the rail 150 is positioned beneath the conveyor belt 110, the products 120 may simply roll or slide along the rail 150 under the force of gravity after being diverted by the twister 140. Alternatively, the rail 150 may drive the products 120 thereon. Any conventional type of drive mechanism may be used with the rail 150. The rail 150 may be any conventional type of substantially rigid material or the rail 150 may be similar to the conveyor belt 110. The rail 150 may have a number of sidewalls so as to keep the products 120 thereon.
The rail 150 may lead to an alternative conveyor system 160. The alternative conveyor system 160 also may include a conveyor belt 170. The conveyor belt 170 may be identical or similar to the conveyor belt 110 described above and may be driven in a similar manner. Positioned on the conveyor belt 170 of the alternative conveyor system 160 may be a number of containers 180.
The containers 180 may be of conventional design. The containers 180 may be made out of conventional paperboard, cardboard, corrugated board, plastic, or any
other conventional type of packaging material In the example of Fig 1 , the containers 180 are provided as a six-pack 190 designed to accommodate the products 120 in a two by three array, l e , two rows of three products 120 each Numerous other configurations for the containers 180 are possible In use, the twister 140 is attached to the conveyor belt 110 The products 120 on the first row 131 of the conveyor belt 110 encounter the twister 140 The twister 140 rotates the products 120 from their upπght and vertical orientation to their rolling and hoπzontal oπentation The products 120 may roll or slide down the rail 150 and into the containers 180 Once each container 180 is filled with the products 120, the containers 180 continue down the alternative conveyor system 160 for sealing and distribution to the retail outlet and the consumer The rail 150 may have a stopper bar or a similar device positioned above the alternative conveyor system 160 such that the bar may stop the flow of the products 120 between each of the containers 180 The bar may be a timed mechanism or a conventional sensor may be used so as to time the activation of the bar with the positioning of the containers 180 or the flow of the products 120
Fig 2 shows a conveyor system 200 similar to that described above This conveyor system 200 diverts two of the rows 130, the first row 131 and the second row 132, to the alternative conveyor system 160 The conveyor system 200 therefore has a first twister 210 and a second twister 220 The first twister 210 extends from the first row 131 to a first rail 230 while the second twister 220 extends from the second row 132 to a second rail 240 Any of the rows 130 may be used The configuration of the twisters 210, 220 and the rails 230, 240 are similar to that descnbed above with respect to Fig 1 In this embodiment, the container 180 is a twelve pack 250 loaded in a two by two by three array, l e , two lanes with two rows and three columns The first rail 230 fills a first lane 251 and the second rail 240 fills a second lane 252 Any similar configuration of the container 180 as filled by the two rails 230, 240 may be used It also is understood that any number of the twisters 210, 220 and the rails 230, 240 may be used with the products 110 and the containers 180 in many different configurations
Fig 3 shows a further embodiment of the present invention, a conveyor system 300 The conveyor system 300 may have the conveyor belt 100 as described above or similar thereto The conveyor system 300 also diverts one or more rows 130 of the products 120 from the conveyor belt 110 to the rail 150 via the twister 140 In this embodiment, the rail 150 leads to an alternative conveyor system 310 The alternative conveyor system 310 has a conveyor belt
320. The conveyor belt 32 J may be driven in a conventional manner. The conveyor belt 320 may have a plurality of supports 330 positioned thereon. Positioned within each pair of the supports 330 may be a container 340. As is shown, the container 340 may be a six-pack 350 in the shape of a triangle. A tip 360 of the triangle six-pack 350 extends through each pair of the supports 330 such that the six-pack 350 rests upon the supports 330. Six of the products 120 are loaded through a base 370 of the triangle six pack 350 in a one by two by three array. Although the use of the conveyor belts 320 and the supports 330 are described herein, the alternative conveyor system 310 may have any conventional means for driving or supporting the container 340. Likewise, the container 340 may have any desired shape or configuration. After the products 120 are loaded within the container 340, the containers 340 are sealed and distributed to the retail outlet and the consumer.
A further embodiment of the present invention is shown in Fig. 4, a conveyor system 400. The conveyor system 400 is identical to the conveyor system 300 of Fig. 3, with the difference that two rows 130 of the products 120 on the conveyor belt 110, the first row 131 and the second row 132, are diverted via a first twister 410 and a second twister 420 to the alternative conveyor system 310. Any of the rows 130 may be used. The first twister 410 leads to a first rail 430 while the second twister 420 leads to a second rail 440. The first and the second rails 430, 440 lead to a container 450. In this case, the container 450 is a triangularly shaped twelve pack 460 loaded in a two by one by two by three form, i.e., the twelve pack 460 is loaded with two lanes of six products 120 each similar to that described with respect to the container 340. Any number of the twisters 410, 420 and the rails 430, 440 may be used with any number or configuration of the products 120 and the containers 450.
Numerous variations on the present invention are possible. For example, Fig. 5 shows a conveyor system 500 of the present invention. The conveyor system 500 has the conveyor belt 110 with the products 120 thereon as described in Fig. 1. The conveyor system 500 also has the twister 140. In this example, the twister 140 leads to a rail system 510. The rail system 510 has a first rail 520 that extends from the first row 131 of the conveyor belt 110. The first rail 520 then takes a vertical dip 530 before extending on towards an alternative conveyor system 540. A second rail 550 may be positioned on top of the first rail 520 and may extend from about the dip 530 to the alternative conveyor system
540. The second rail 550 may be spaced apart from the first rail 520 at slightly more than the average width or dimension of the typical product 120 used therein.
Positioned on top of the second rail 550 may be a third rail 570. The third rail 570 essentially may follow the path of the second rail 550 and the first rail 520. The third rail 570 is spaced apart from the second rail 550 also by slightly more than the average width or dimension of the typical product 120. Any number of rails 520, 550, 570 may be used. Positioned over the third rail 570 may be a stopper
580. The stopper 580 may be a substantially rigid member positioned along the path of the rail system 510 so as to stop or divert the flow of the products 120.
In use, the products 120 are diverted from the first row 131 by the twister 140. The products 120 may roll or slide down the first rail 520 under the force of gravity. The products 120 roll down the first rail 520 and down through the dip 530. Once the first rail 520 is full of the products 120, the products 120 continue to roll down the first rail 520 and then into the second rail 550. Similarly, after the second rail 550 is full, the products 120 continue to roll down the first rail 520 until they encounter the stopper 580. The products 120 then roll down the third rail 570.
Positioned on the alternative conveyor system 530 are a number of containers 590. As is shown, the containers 590 may be in the shape of a substantially triangular six-pack 600. Three of the products 120 roll off of the first rail 520 and into the container 590. Two of the products 120 roll off of the second rail 550 and into the container 590. One of the products 120 rolls off of the third rail 570 and into the container 590. The rails 520, 550, 570 of the rail system 510 may each have a length that corresponds to the number of the products 120 that are intended to be delivered to the container 590. In other words, the first rail 520 may be three times as long, and hold three times as many products 120, as the third rail 570. Any number or configuration of the rails 520, 550, 570 and the stoppers 580 may be used with any configuration of the products 120 and the containers 590.
Fig. 6 shows a conveyor system 610. The conveyor system 610 is identical to that described above with respect to the conveyor system 500, but with the use of an expanded rail system 510. In other words, a first rail 620, a second rail 630 and a third rail 640 of Fig. 6 are about twice the width of the first rail 520, the second rail 550 and the third rail 570 respectively of Fig. 5. Any desired width may be used. A first twister 642 and a second twister 644 lead to the rails 620, 630, 640 in a manner similar to that described above. These rails 620, 630, 640 in turn lead to the alternative conveyor system 530 with a container 650 that may be in the shape of a substantially triangular twelve pack 660. Any number or
configuration of the rails 620, 630, 640 and the stoppers 580 may be used with any configuration of the products 120 and the container 650.
Fig. 7 shows a further embodiment of the present invention. This embodiment shows a conveyor system 700. The conveyor system 700 has a conveyor belt 710 with a number of rows 720 of the products 730 thereon. The conveyor belt 710 may be identical or similar to the conveyor belts described above. In Fig. 7, five rows 720 of the products 730 are shown, a first row 721, a second row 722, a third row 723, a fourth row 724, and a fifth row 725. As in the previous embodiment, the first row 721 has a first twister 740 positioned thereon. The first twister 740 may be identical or similar to the twisters described above.
The first twister 740 leads to a first rail 750. The first twister 720 rotates the products 730 from their vertical and upright orientation to their horizontal and rolling orientation such that the products 730 will roll down the first rail 750 as described above. The first rail 750 in turn leads to a first distribution system 760.
The first distribution system 760 includes a first cover rail 770 positioned adjacent to the first rail 750. The first rail 750 and the first cover rail 770 are spaced apart by slightly more than the typical width or dimension of the products 730. The first rail 750 and the first cover rail 770 form a pathway for the products 730 as they exit the conveyor belt 710. The first rail 750 and the first cover rail 770 then expand in width so as to provide for several columns 780 of the products 730. By "column", we mean any orientation of the products 730 including a row, a lane, or any other position or direction. As the first rail 750 and the first cover rail 770 expand in width, the products 730 may be divided into the columns 780 via a divider 790. The divider 790 may be a substantially rigid member that divides the products 730 into a first column 800 and a second column 810. The divider 790 may be substantially triangular in shape as is shown or may be any other convenient shape. The first rail 750 and the first cover rail 770 may then continue to expand until the first column 800 and the second column 810 also expand into a third column 820 and a fourth column 830. As many columns 780 as desired may be used.
The products 730 may then encounter a second twister 840. The second twister 840 rotates the products 730 from the horizontal and rolling or sliding orientation back to the upright and vertical orientation. The twister 840 may be of the same or similar design, configuration, and materials as the twisters described above. After being rotated, the products 730 may then drop through a number of tubes 850. In Fig. 7, four tubes 850 are shown, a first tube 851, a
second tube 852, a third 853, and a fourth tube 854. The number of the tubes 850 is based, in part, on the number of the columns 800, 810, 820, 830. The tubes 850 may be made of any substantially rigid material and may have a diameter at least slightly larger than the diameter of the products 730. The products 730 may fall through the tubes 850 under the force of gravity or the products 730 may be driven therethrough by conventional means. The tubes 850 may be positioned over an alternative conveyor system 860.
The alternative conveyor system 860 may be identical or similar to any of the conveyor systems described above. The alternative conveyor system 860 may have a number of containers 870 positioned thereon. In this case, the containers 870 may take the shape of an open-ended twelve pack 880 having three rows of four products 730 each. The containers 870 may have any number of rows or products 730 therein. In this case, a first row 871, a second row 872, and a third row 873, are used. The products 730 of the first distribution system 760 may fall out of the tubes 850 under the force of gravity and into the first row 871 of the containers 870.
The first row 721 of the conveyor belt 710 also may have a first diversion rail 890 thereon. The first diversion rail 890 may extend from the second row 722 of the conveyor 710 to the first row 721 so as to allow some or all of the products 730 on the second row 722 to move to the first row 721. The first diversion rail 890 generally is positioned down stream of the first twister 740. A second distribution system 900 may be positioned down stream of the first diversion rail 890. The second distribution 900 system also has a first twister 910 and each of the elements described above in the first distribution system 760. The second distribution system 900 fills the second row 872 of the containers 970 with the products 730 as was described above with respect to filling the first row S71. Likewise, a second diversion rail 920 may be positioned down stream of the first diversion rail 890 so as to lead to another first twister 930 and a third distribution system 940. The third distribution system may be identical or similar to the other distribution systems 760, 900. The third distribution system 940 may fill the third row 873 of the containers 870. Any number of distribution systems 760, 900, 940 may be used so as to fill any type or configuration of the containers 870 with any number of the products 730.
As is shown in Fig. 8, the conveyor system 700, or any similar system, may be modified with the use of a number of stoppers 950. The stoppers
950 may be any type of substantially rigid material positioned in the pathway of the products 730. The stoppers 950 may be fixedly attached or the stoppers 950
may be movable such that the stoppers 950 may be maneuvered upon command or at a given interval. In tlis embodiment, the stoppers 950 block one or more rows 780 near the second twisters 810, or elsewhere, so as to limit the number of products 730 entering the tubes 850. By varying the number of tubes 850 in use in one or more of the distribution systems 760, 900, 940, the conveyor system 700 can fill containers 870 in unusual and unlimited configurations. In addition to the stoppers 890, the second twisters 810 and the tubes 850 may be connected by flexible tubing 955 so as to permit even greater adaptability in filling the containers 770. For example, Fig. 8 shows the conveyor system 700 filling a container 870 in the shape of a hexagon 960 holding seven of the products 730.
As described above, almost any configuration of the containers 870 with almost any number of the products 730 may be used.
Figs. 9A - 9E show further examples of various types of the containers 870 that may be produced with the conveyor systems described herein. For example, Fig. 9A shows the twelve pack 880 that may be produced in the conveyor system 700, i.e., the twelve pack 880 has three rows of four products 730 with each row 871, 872, 873 filed by one of the distribution systems 760, 900, 940. Fig. 9B shows the use of two side-by side six packs 970. The six packs 970 may be produced in the manner similar to that found in the conveyor system 700 with an amount of separation between the first and second tubes 851, 852 and the third and fourth tubes 853, 854. Fig. 9C shows the creation of the seven packs 960 as produced by the conveyor system 700 described in Fig. 8. Likewise, Fig. 9D shows a fourteen pack 980 that may be created by the conveyor system 700 of Fig. 8. After a first seven pack 961 is filled, another seven pack 962 may be filled on top of the first seven pack 961 so as to form the fourteen pack 980. Finally,
Fig. 9E shows a triangular six pack 990 that may be produced by the conveyor system 700 with the first distribution system 760 having three tubes 850, the second distribution system 900 having two tubes 850, and the third distribution system 940 having one tube 850. Alternatively, a number of the stoppers, 950 may be used in a manner similar to that shown in the conveyor system of Fig. 8 to produce the six pack 990.
It should be apparent that almost any configuration of container may be filled through the present invention. Further, the various configurations can be quickly altered via the use of the rails, the twisters, the distribution systems, and the stoppers as described herein. Significantly, the present invention may be quickly attached or removed from existing conveyor lines so as to provide unique configurations of containers in a timely fashion. As such, multi-packs of
desired configurations and shapes can be separately packaged while maintaining and utilizing the existing can packing line. Further, because the invention is driven largely by gravity, adapting the existing lines does not require significant mechanical or electrical resources. The conveyor systems described herein also can be used with different filling lines such that mixed multi-packs may be created. In other words, one of the conveyor systems herein may be used with one type or flavor of a product on one packing line while a second conveyor system may be used with a different type or flavor of products on a second packing line so as to provide unique multi-packs. Special multi-packs therefore can be filled at the same time traditional multi-packs are filled on the existing filing lines.
Multi-product multi-packs are desirable to provide customers with a product selection choice. Additionally, specially shaped multi-packs can be utilized on a project or seasonal basis. Various configurations of multi-packs can provide advantages in marketing and transportation. The invention thus provides flexibility in adapting an existing line to fill any number of different containers.