FOOD PACKAGING CLOSING SYSTEM AND METHOD THEREFOR

Abstract

The present disclosure includes a system and method for closing cartons. The present disclosure includes a flap bending system, having a first end and a second end, configured to receive an object at the first end of the flap bending system and to bend the flap of an object. The present disclosure also includes a progressive closing system that allows an egg carton to be gently closed while in motion without requiring the carton to stop.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/107,402 filed on Jan. 24, 2015, U.S. Provisional Application No. 62/107,403 filed Jan. 24, 2015, and U.S. Provisional Application No. 62/107,405 filed Jan. 24, 2015, the contents of which are incorporated herein by reference in their entirety.

BACKGROUND

Field of the Invention

The invention relates generally to the field of food product processing, and more particularly to egg processing.

In the egg packing industry, eggs typically undergo a great deal of processing before they are ready to be sold to the consuming public. In many circumstances, for example, eggs pass through several processing stations where they are washed, candled, weighed, graded, and packed into packages (e.g., cartons, crates; or other commercially distributed containers). Examples of such processing stations and mechanisms for conveying eggs from station to station are described, for instance, in the following U.S. patents assigned to Diamond Automations, Inc. (U.S. Pat. Nos. 4,189,898; 4,195,736; 4,505,373; 4,519,494; 4,519,505: 4,569,444; 4,750,316; 5,321,491; and 6,056,341) and TEN Media LLC (U.S. Pat. No. 8,455,030), which are incorporated herein by reference in their entirety. As a reference, it is not uncommon for a facility in which these stations operate to output about one million eggs in a single day. Accordingly, to be commercially acceptable, the throughput of the stations needs to be quite high, with some stations typically processing on the order of 20,000 eggs per hour.

The Egg Packing Industry uses devices known as “packers” to pack the eggs into the packages. Typically, a packer includes a conveyor (e.g., a belt conveyor, roller conveyor, chain conveyor, etc.) that moves empty packages through an egg loading section (where the eggs are loaded into the egg loading section from above) and then moves the filled packages to a package closing section that is responsible for closing the lids of the packages. The eggs may be supplied to the egg packer via a grader system.

Recently in the egg packing industry, there has been an effort to mark the eggs produced with a freshness date, traceability code, and advertisements—see U.S. Patent Application Publication No. U.S. 2014/0085397, titled “Methods And Apparatus For Storing And Retrieving Information Relating to Edible Objects,” to B. E. Parker, published Mar. 27, 2014, which is hereby incorporated by reference in its entirety.

Unfortunately, the marking operation requires that the eggs in the egg packages (such as, for example, the packages 112, 114, 116, and 118, shown in FIG. 1, which may simply be referred to as egg cartons or just “cartons”) be exposed to the egg marking system (not shown), and therefore the egg cartons would remain in an open configuration when they are ejected from the egg marking system. These cartons must be closed before they can be shipped to resellers and should be closed as part of the normal process of moving the cartons through the moving conveyor system of the packer. Due to the variety of egg cartons used in the industry, there are multiple methods that egg carton makers use to lock their cartons in a closed position. Additionally, even without the need to mark the eggs, the cartons should be closed after the eggs have been packed into the cartons by the packer.

One variety of egg cartons uses a tucker flap which contains locks to secure the lid of the carton in a closed position. Generally, when these types egg cartons are produced, the tucker flap remains in a horizontal position (i.e., approximately parallel to the plane of movement) and must therefore first be folded upward beyond vertical (i.e., beyond perpendicular to the plane of movement) before the carton lid may be closed because the lid must be folded over the flap and pressed into place. Sometimes, due to issues arising during the manufacturing process, these tucker flaps may be folded below horizontal or require additional force to bend upwards. In general, the force required to close the flap, mechanical tolerances and variances of the flap, poor or absent scoring at the hinge of the flap and body of the carton render the process mechanically challenging. Many known products in the marketplace perform the closing process with poor reliability and contribute to machinery down time.

As such, a mechanism which can bend the flap more than 90 degrees is advantageous to close cartons of this type because a method of using a device which is both a pushing pin and an active lever capable of folding the flap in some variations can obviate this problem.

Additionally the typical packer machinery closes the carton when the carton is stationary on the conveyor. In order not to slow down the packing process (and thereby the overall egg processing rate of the egg processing facility), this closing action must be completed within the time that the carton is stationary in the normal egg packing process. This can be as little as 700 ms. The complex mechanical process required to close and latch the carton requires a sequence of steps as described above. The complete process must be completed within the available time. Therefore the process requires fast-moving levers and arms. If the carton is improperly manufactured, or mis-aligned with the closing mechanisms, the fast lever motion can impact the carton in unintended ways and eggs can be ejected from the carton. These ejected eggs cause two problems—firstly they can break and leak, causing egg debris to contact subsequent cartons processed before the debris is cleaned up (such cartons typically being unacceptable for retailers and consumers, and needing to be scrapped), and secondly if the carton is closed, one or more eggs may be missing. Missing eggs are typically detected only prior to the closing station (detection of a missing egg triggers that the closing mechanism not activate, and that the carton be left open). Therefore the packing machine operator would be unaware that the egg was missing, and this leads to retailer and consumer dissatisfaction.

Additionally packer machinery is frequently installed at facilities classified as Agricultural. Some of these facilities do not need to comply with certain Occupational Health and Safety and machinery guarding laws as do most business establishments. A combination of the high speed of existing mechanical components used in the packing process, existing designs, and a lower standard of Occupational Health and Safety render the existing packer equipment hazardous to adjust and maintain.

The disclosed mechanism closes the cartons in a slow, progressive manner, ensuring that the egg-ejecting impacts noted above do not occur. Although manufacturing defects and misalignment can still occur, this closing mechanism reduces the likelihood of egg debris on subsequent cartons, and of missing eggs caused by the closing mechanism itself, and is safer than existing equipment for humans in the operating vicinity of the equipment.

BRIEF SUMMARY

The following presents a simplified overview of the example embodiments in order to provide a basic understanding of some aspects of the example embodiments. This overview is not an extensive overview of the example embodiments. It is intended to neither identify key or critical elements of the example embodiments nor delineate the scope of the appended claims. Its sole purpose is to present some concepts of the example embodiments in a simplified form as a prelude to the more detailed description that is presented later.

In accordance with the embodiments herein, the present disclosure includes a system and method for closing cartons. In a preferred embodiment, the present disclosure includes a flap bending system, having a first end and a second end, configured to receive an object at the first end of the flap bending system and to bend the flap of an object. The flap bending system may include a flap bending system conveyor defining a flap bending system conveyor movement path and configured to move the object from the first end to the second end of the flap bending system at a flap bending system conveyor speed and a hold-back pin having a first end and a second end, the hold-back pin configured to move at a hold-back pin speed along the flap bending system conveyor movement path and to contact the object, wherein the contact by the holdback pin is configured to inhibit the object from moving along the flap bending system conveyor at greater than the hold-back pin speed. The flap bending system may also include a flap bending arm having a first end and a second end, the flap bending arm configured to move at a flap bending arm speed along the flap bending system conveyor movement path and to contact a flap of the object, wherein the contact by the flap bending arm is configured to bend the flap of an object.

In another preferred embodiment, the present disclosure includes a carton lid closing system which employs progressive closing action. After a flap bending system has bent the flap of an egg carton, the egg carton remains on the conveyor chain and is pushed towards the carton lid closing system. A pair of carton lid flippers is positioned along the path of the conveyor chain and therefore in the path of any egg cartons moving along the conveyor chain. These carton lid flippers have two configured positions—the “open” position and the “flipping” position—and may alternate between these two positions via use of any type of actuating mechanism. In this particular example, the carton lid flipper is attached at one end to a solenoid and a spring. When inactivated, the spring returns the carton lid flipper into the “flipping” position. When active, the solenoid rotates the carton lid flipper to the “open” position.

Still other advantages, aspects and features of the subject disclosure will become readily apparent to those skilled in the art from the following description wherein there is shown and described a preferred embodiment of the present disclosure, simply by way of illustration of one of the best modes best suited to carry out the subject disclosure As it will be realized, the present disclosure is capable of other different embodiments and its several details are capable of modifications in various obvious aspects all without departing from the scope herein. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated herein and forming a part of the specification illustrate the example embodiments.

FIG. 1 is an example of a known egg packing system.

FIG. 2 is an example of another known egg packing system.

FIG. 3 shows an example of an embodiment of a flap bending system utilizing active cleats.

FIG. 4 shows another example of an embodiment of a flap bending system utilizing active cleats.

FIG. 5 shows another example of an embodiment of a flap bending system utilizing active cleats.

FIG. 6 shows an example of an embodiment of the carton lid closing system which employs this progressive closing action in accordance with the present disclosure.

FIG. 7 shows another example of an embodiment of the carton lid closing system which employs this progressive closing action in accordance with the present disclosure.

FIG. 8 shows another example of an embodiment of the carton lid closing system which employs this progressive closing action in accordance with the present disclosure.

FIG. 9 shows another example of an embodiment of the carton lid closing system which employs this progressive closing action in accordance with the present disclosure.

FIGS. 10A through 10D show different views of the active cleats in operation along a packer in accordance with the present disclosure.

FIGS. 11A through 11B show additional different views of the active cleats in operation along a packer in accordance with the present disclosure.

FIGS. 12A through 12B show additional different views of the active cleats in operation along a packer in accordance with the present disclosure.

FIGS. 13A through 13B show additional different views of the active cleats in operation along a packer in accordance with the present disclosure.

FIGS. 14A through 14C show additional different views of the active cleats in operation along a packer in accordance with the present disclosure.

FIGS. 15A through 15D show additional aspects of the carton lid closing system in accordance with the present disclosure.

FIGS. 16A through 16D show additional aspects of the carton lid closing system in accordance with the present disclosure.

FIGS. 17A through 17D show additional aspects of the carton lid closing system in accordance with the present disclosure.

FIGS. 18A through 18D show additional aspects of the carton lid closing system in accordance with the present disclosure.

FIGS. 19A through 19D show additional aspects of the carton lid closing system in accordance with the present disclosure.

FIG. 20 shows additional aspects of the carton lid closing system in accordance with the present disclosure.

FIGS. 21A through 21B show additional aspects of the carton lid closing system in accordance with the present disclosure.

FIGS. 22A through 22B show additional aspects of the carton lid closing system in accordance with the present disclosure.

FIG. 23 shows additional aspects of the carton lid closing system in accordance with the present disclosure.

FIG. 24 shows additional aspects of the carton lid closing system in accordance with the present disclosure.

FIG. 25 shows additional aspects of the carton lid closing system in accordance with the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This description provides examples not intended to limit the scope of the appended claims. The figures generally indicate the features of the examples, where it is understood and appreciated that like reference numerals are used to refer to like elements. Reference in the specification to “one embodiment” or “an embodiment” or“an example embodiment” means that a particular feature, structure, or characteristic described is included in at least one embodiment described herein and does not imply that the feature, structure, or characteristic is present in all embodiments described herein.

In general, the embodiments herein provide methods and systems for food packaging. Embodiments of the present disclosure are directed to an apparatus as well as a method for closing carton lids and then disengaging therefrom. While reference is made herein to eggs in particular, it should be understood that this disclosure is directed to all food products that may be sorted and subsequently packed via a conveyor-based system.

In FIG. 1, an egg packing system 100 is shown having a plurality of packers 102, 104, 106 and 108 and a grader system 110 that passes the eggs to the packers which pack the eggs into packages 112, 114, 116, and 118. Similarly, FIG. 2 shows another egg packing system 200 that includes a grader system 202, a plurality of packers 204, 206, 208, 210, 212, and 214.

Flap Bending System—Active Cleats

FIGS. 3 through 5 show an example of an embodiment of a flap bending system utilizing active cleats. In the embodiment contained therein, a conveyor chain 306 is powered by a conveyor gear 302. During operation, the conveyor gear 302 rotates counterclockwise such that the conveyor chain 306 shown in FIG. 3 travels from the right side to the left side of the carton closing system. Attached to the conveyor chain 306 are pusher paddles 320. The pusher paddles 320 are attached to the conveyor chain 306 using a paddle plate 321 attached to a single link of the conveyor chain 306. This rigid connection allows the pusher paddle 320 to push an egg carton along the movement path of the conveyor chain 306.

Guide shaft tracks 310 are used to control the movement and timing of the hold-back pin 322 and flap bending arm 326 (i.e., an active cleat). In this embodiment, the guide shaft tracks 310 appear on both sides of the conveyor chain 306 and are carved into panels along the side of the carton closer system. It should be appreciated that the guide shaft tracks 310 can be separated from the panels. Furthermore, guide shaft tracks 310 can be separated into both a hold-back pin track and flap bending arm track if a greater degree of control over movement and timing of the hold-back pin 322 and flap bending arm 326 are desired.

A hold-back pin 322 is used to inhibit the egg carton from being pushed by flap bending arm 326 during the flap bending operation (discussed below). One end of the hold-back pin 322 is attached to the hold-back pin plate 323 using a hold-back pin connection shaft 324. This method of connection allows the hold-back pin 322 to freely rotate about the central axis of the hold-back pin connection shaft 324. At the second end of the hold-back pin 322 is a hold-back pin guide shaft 325. In this embodiment, the hold-back pin 322 and the hold-back pin guide shaft 325 are a single unit. The hold-back pin guide shaft 325 is inserted into the guide shaft track 310. During operation, the movement of the conveyor chain 306 pulls the hold-back pin 322 along the path of the conveyor chain 306. While this motion is occurring, the hold-back pin guide shaft 325 is also following the path of the guide shaft track 310 resulting in rotation of the holdback pin 322. This rotation allows the hold-back pin 322 to activate and “lock” the egg carton in place. The guide shaft track 310 therefore serves as a timing mechanism, based upon the location of the hold-back pin 322, for activation of the hold-back pin 322.

A flap bending arm 326 is used to bend the flap of the egg carton. The flap bending arm 326 is attached to the pusher paddle 320 using a flap bending arm connection shaft 327. This method of connection allows the flap bending arm 326 to freely rotate about the central axis of the flap bending arm connection shaft 327. At one end of the flap bending arm 326 is a flap bending arm guide shaft 328. In this embodiment, the flap bending arm 326 and the flap bending arm guide shaft 328 form a single unit. The flap bending arm guide shaft 328 is inserted into the guide shaft track 310. During operation, the movement of the conveyor chain pulls the flap bending arm 326 along the path of the conveyor chain 306. While this motion is occurring, the flap bending arm guide shaft 328 also follows the path of the guide shaft track 310 resulting in rotation of the flap bending arm 326 around the flap bending arm connection shaft 327. This rotation allows the flap bending arm 326 to activate and bend the flap of the egg carton.

The general operation and timing of this particular embodiment is as follows. Pusher paddle 320 pushes the egg carton from the right side to the left side of the carton closing system as viewed in FIG. 3. Upon a first point along the path of the conveyor chain 306, the hold-back pin 322 begins to activate as a result of a change in the guide shaft track 310 and the hold-back pin 322 is positioned underneath the bottom of the egg carton. After the hold-back pin 322 is in its fully activated position, the flap bending arm 326 begins to activate as a result of the same change in the guide shaft track 310. The rotation of the flap bending arm 326 folds the tucker flap from a horizontal position to beyond vertical (greater than 90 degrees). This embodiment also allows for the bending of tucker flaps even when the tucker flaps are in disadvantageous positions (i.e., below horizontal). As shown in this embodiment of the flap bending arm 326, the use of a tapered design on one end of the flap bending arm 326 prevents damage from occurring to the eggs, the carton lid, or the tucker flap. It should be noted that the activation of the flap bending arm 326 and the rigidity of egg carton may cause the egg carton to be pushed off the pusher paddles 320 and therefore inhibit the flap bending arm 326 from bending the tucker flap. However, due to the activation of the hold-back pin 322, the egg carton is restrained from being pushed forward and off the pusher paddle 320. As a result, all of the force applied by the flap bending arms 326 is used to fold the tucker flap.

At a second point along the path of the conveyor chain 306, the hold-back pin 322 is deactivated as a result of a change in the guide shaft track 310. This section of guide shaft track 310 is depicted as the section of the track 311. Following this event, the flap bending arm 326 is deactivated as a result of the same change in the guide shaft track 310 and is allowed to “float” in the egg carton. That is, the flap bending arm 326 is allowed to freely rotate in the egg carton. This “floating” allows the flap bending arm 326 to better conform to the shape of the egg carton prior to the carton extraction process.

In some embodiments of the present disclosure, the active cleats/flap bending arms push the carton up into the carton lid closing system. It is appreciated that without the active cleats and hold-back pins, the tucker flap is not consistently folded into position.

Carton Lid Closing System

After the flap bending system, has bent the tucker flap of the egg carton, or in cases where there is no tucker flap, it is preferred that the lid of the egg carton be closed. In order to protect the eggs contained in the egg container, a design which employs a progressive closing action, rather than an instantaneous one, provides additional safeguards against breakage of eggs.

FIGS. 6 through 9 represent an example of an embodiment of the carton lid closing system which employs this progressive closing action. In the embodiment contained therein, after the flap bending system 300 has bent the flap of the egg carton, the egg carton remains on the conveyor chain 306 and is pushed towards the carton lid closing system. A pair of carton lid flippers 350 is positioned along the path of the conveyor chain 306 and therefore in the path of any egg cartons moving along the conveyor chain 306. These carton lid flippers 350 have two configured positions—the “open” position (as shown in FIG. 8) and the “flipping” position (as shown in FIGS. 6 and 7)—and may alternate between these two positions via use of any type of actuating mechanism. In this particular example, the carton lid flipper 350 is attached at one end to a solenoid and a spring. When inactivated, the spring returns the carton lid flipper 350 into the “flipping” position. When active, the solenoid rotates the carton lid flipper 350 to the “open” position. This configuration is useful because flats (i.e., 30-egg packaging) do not have a lid, and the spring allows them to ride over the arms and press them down with the flats' weight without needing to activate the solenoid, thereby improving its life. Additionally the use of the spring-return as implemented, allows cartons that are already closed (in a laser marking system this includes cartons which do not require marking) to flow over the arms without tipping or otherwise impeding the smooth flow of cartons.

In an alternate embodiment, however, the system can be configured such that, when activated, the solenoid rotates the carton lid flipper 350 into the “flipping” position. When inactive, the spring returns the carton lid flipper 350 to the “open” position. However, it should be appreciated that many other methods of changing the configured position of the carton lid flipper 350 exists and that a spring can be omitted. The carton lid flipper 350 may be changed from one configured position to the next solely through the use of the actuating mechanism.

While in the “open” position, the carton lid flipper 350 is rotated so that no part of the carton lid flipper 350 protrudes beyond the plane formed by the conveyor chain 306. As a result, egg cartons are allowed to continue along the path of the conveyor chain 306. This position may be employed in multiple circumstances. For example, this position may be employed after the lid of the egg carton has been partially closed and the lid has made contact with the carton lid closing heel 352 to allow the carton lid closing heel 352 and carton lid hold-down bars 360 to complete the process of closing of the egg carton. This position may also be employed to allow an egg carton to bypass the closing process such as when there are eggs missing from a closeable carton, or when there is no lid to close on the egg carton (e.g., egg flats).

While in the “flipping” position as shown in FIG. 7, one segment of the carton lid flipper 350 forms an angle with the conveyor chain 306. In this particular embodiment, this segment spans from the conveyor chain 306 to the carton lid closing heel 352. During operation, with the egg carton moving from right to left as viewed from FIG. 7, the lid of the egg carton is partially closed as a result of contacting the angled segment of carton lid flipper 350 and the force of the pusher paddle 320 pushing the egg carton along the path of the conveyor chain 306.

At a location further down the path of the conveyor chain 306, a carton lid closing heel 352 is employed to further close the lid of the egg carton. The carton lid closing heel 352 is suspended above the conveyor chain 306 at a height slightly lower than that of the egg carton in its fully closed position. In some embodiments, the closing heel 352 is between ⅛″ and ½″ lower than that of the egg carton in its fully closed position so that the heel 352 applies force even when the carton is fully closed already before leaving that section of the conveyor, as sometimes happens depending on the carton design. The carton lid closing heel 352 is attached to two removable plates 342 through the use of carton lid closing heel shafts 353. Attachment to removable plates allows for the carton lid closing heel 352 to be removed for cleaning and assembly. The design allows for rotation along the central axis of one of the carton lid closing heel shafts 353. This allows the carton lid closer 352 to adjust in height to better conform to the shape of the egg carton and to inhibit any damage to its contents. The carton lid closing heel 352 may also be locked at a certain height to inhibit any damage to eggs in cartons without a lid. In this particular embodiment, a roller 354 is used to make contact with the egg lid during the process. Use of a roller 354 allows for the carton lid closing heel 352 to more easily close lids which are unevenly shaped. During operation, the carton lid closing heel 352 receives the partially closed lid of the egg carton from the carton lid flipper 350 and, via forces applied by the pusher paddles 320 to the egg carton, more completely closes the lid of the egg carton. In an some embodiments, the lower limit of movement of the carton closing heel 352 can be adjusted to allow fine-tuning to accommodate different carton designs.

At a location immediately following the carton lid closing heel 352 are carton lid hold-down bars 360. One section of the carton lid hold-down bars 360 is approximately parallel to the plane of the conveyor chain 306. The second section of the carton lid hold-down bars 360 are tapered upward to accommodate for the potential of lids which were not fully closed by the carton lid closing heel 352. The carton lid hold-down bars 360 are attached to the two removable plates 342 through the use of carton lid hold-down bar shafts 361. Attachment to removable plates allows for the carton lid hold-down bars 360 to be removed for cleaning and assembly. The design allows for rotation along the central axis of one of the carton lid hold-down bar shafts 361. This rotation allows the carton lid hold-down bar 361, like the carton lid closing heel 352, to adjust in height and better conform to the shape of the egg carton and inhibit any damage to its contents. The carton lid hold-down bars 360 may also be locked at a certain height to inhibit any damage to eggs in cartons without a lid. In some embodiments, the carton lid hold-down bars 360 may have a lower limit that is adjustable for carton designs. During operation, the carton lid hold-down bars 360 both close any potentially partially open egg cartons and inhibit the carton lid of the egg carton from reopening during the process of carton removal (described below). The carton lid hold-down bars 360 also provide a slight degree of friction between the egg carton and the conveyor chain 306 which ensures that the egg cartons remain on the pusher paddles 320 during the entire operation.

Carton Disengagement System

Upon lid closure, the flap bending arm 326 remains “floating” in the egg carton. Failure to raise the carton prior to ejecting the egg carton from the carton closer system may result in either damage to the carton, to the eggs within the carton, or both. As such, a carton disengagement system has been created to assist in disengaging the flap bending arm 326 from the egg carton prior to ejection from the system.

FIG. 9 represents one embodiment of the carton disengagement system. In this embodiment, a rising raceway 370 (i.e., closer ramp) is used which angles the egg carton up. A set of main cleats 372 are used to push the egg carton through the rising raceway 370. Immediately following the rising raceway 370 is a flat surface. As a result of the flap bending arm 326 “floating” in the egg carton combined with the angled rising raceway 370, the flap bending arm 326 is disengaged from the egg carton.

In existing mechanisms the carton is closed when stationary. In order to maintain processing speed of the egg packing equipment, the dosing action is normally completed in a short time, which can cause damage to the eggs or carton. Damage to any one of the eggs in the carton results in loss of the complete carton. Additionally some carton designs are difficult to close in a short time using such mechanisms.

As such, in a preferred embodiment, the described closer ramp (i.e., the rising raceway) closes the cartons in a progressive manner, while the cartons are moving. The closer ramp reduces the forces on the carton and eggs, resulting in a smoother, gentler and more consistent dosing mechanism. This eliminates waste of eggs and cartons.

In some embodiments, the system uses cleats to both push the carton, and close the minor flap before the lid has been folded over the eggs and minor flap. The cleats also retain the carton while the minor flap is being closed. The ramp in the bed for the cartons gently raises the carton to withdraw the cleat once it has closed the minor flap and the lid is folded over the minor flap. Failure to raise the carton possibly forces either a downwards removal of the cleat (which is difficult in practice) or results in damage to the carton, minor flap or eggs, as the carton exits the conveyor.

In such embodiments, the hold-down bars above the ramp provide gentle, consistent pressure, avoiding damage to the carton or eggs inside. The rotating pivots of the closer bars provide consistent force even as the carton climbs the ramp. The wide hold-down bars provide consistent gentle pressure spread across the lid, to reduce potential for local damage to carton or eggs, and accommodate all known lid, latch, and minor flap types and associated positions for each of them. The ramp in the bed allows smooth carton discharge with reduced acceleration or pinch-points. The described system and method also allows withdrawal of the cleat without placing a shearing force or twisting force on the carton, which might damage the carton. An alternate embodiment may use a flat bed with a cleat conveyor running at a slight angle to the plane of carton movement, thereby gradually withdrawing the cleats from between the closed lid and the folded minor flap.

In an alternate embodiment, the design may have a flat surface without ramp 370 and may also include a downward motion of the flap bending arm 326. In such an embodiment, the flap bending arms may constitute a more complex mechanism in which hinge 327 can be lowered to achieve substantially the same disengagement as described above once the lid is closed over the top of the minor flap.

In some embodiments, the carton disengagement process occurs at the same time that the carton transitions onto a second conveyor mechanism. This second conveyor mechanism may either be self-powered or powered directly by the first conveyor mechanism. In other embodiments, the carton disengagement process occurs at the same time the egg carton is directed to the outfeed of the system.

Turning to FIGS. 10A through 13B, different views of the active cleats are shown in operation along a packer, showing the progressive steps in the folding up of the minor flap. FIGS. 14A through 14C show three views of the same process of folding the flap. The different views show features that include again, the cleats pushing the carton up into the closer and without active cleats, the tucker flap is not consistently folded up into position. In this examples it is shown that the active cleats on their own can push the carton off the main cleats, if the tucker flap is positioned in a number of disadvantageous positions at the time of engagement. The system can hold back the carton as the active cleat is activated.

In this example embodiment, the hold-back pins activate before the active cleat is activated. The holdback pins may be activated using a simple mechanical control track, using only the position of the conveyor to determine pin status/position. The active cleats may be activated using a simple mechanical control track, using only the position of the conveyor to determine active cleat status/position. In one example of an implementation, both control tracks (active cleat and holdback pin) are coincident with one another. The active cleat design may fold up the tucker flaps even when the flaps are in a non-preferred position, folded down below horizontal (parallel with the base of the carton). The active cleat in some variations may have a tapered finger, allowing the lid to close over it without causing damage either to the lid, the tucker flap or the eggs in the carton. At the time of cleat withdrawal, the mechanical track may get wide in profile (as shown in FIG. 3 at track 311), allowing the cleat to ‘float’ and follow the unique profile of the carton being closed. The cleats are insertable and removable from the track via a “reverse direction” entry point in the track. Hold-back pins can be used as the pusher cleats for flats or other non-closed cartons, to avoid carton damage from the active cleat process. Using this approach avoids the potential need for controls to disable the complete active cleat mechanism for this carton. There also exist situations in which using an embodiment with a self-contained cleat mechanism including the activation and deactivate features described above but without a ramp would remove the need for solenoid activation of the flap arm 350. In some embodiments, the track design allows the pins 325 and 328 to take one of two paths. One path activates the active cleat and hold-back pins, the other path does not. If the active cleat is not activated, then the lid can be folded over without latching, and will therefore remain open when leaving the skis 360. This would then allow the lid to be correctly printed with a carton code, for instance, while alerting the machine operator via the deliberately-left-open carton that an egg is missing (or other reason for non-closure). In yet another embodiment, a track switch is included for pins 325 and 328 as well as the solenoid for activating the flippers 350. Such a configuration accommodates cartons without a flap that need to be left open. Finally, the relative position of the pusher cleat and active cleat may be set to accommodate cartons containing 12 eggs, or 18 eggs, or 24 eggs, where such cartons are manufactured in cardboard, fiber, or plastic, to a number of carton designs.

FIGS. 15A through 25 show additional aspects of the carton lid closing system. In particular, FIGS. 15A through 18D show progressive views of a single carton as it passes over the spring-loaded lid flipper bars.

FIGS. 19A and 19D show the heel and hold-down bars in the “active positions while FIGS. 19B and 19C show the held and hold-down bard in the retracted position allowing eggs and cartons to pass through untouched.

FIGS. 20 through 25 show the progressive action of the heel and disengagement ramp on successive cartons.

As described earlier, the cartons are advanced row by row and when a carton has an embedded lid the carton is also closed in process, using a mechanism. In existing mechanisms the carton is closed when stationary. In order to maintain processing speed of the egg packing equipment, the closing action is normally completed in a short time, which can cause damage to the eggs or carton. Damage to any one of the eggs in the carton results in loss of the complete carton. Additionally some carton designs are difficult to close in a short time using such mechanisms. The described carton closer in FIGS. 6 through 25, closes the cartons in a progressive manner, while the cartons are moving. The carton closer reduces the forces on the carton and eggs, resulting in a smoother, gentler and more consistent closing mechanism. This eliminates waste of eggs and cartons.

In general, the carton lid closing system utilizes a closing process that is progressive not instantaneous which results in less potential for damage to eggs and cartons. In general, the carton lid closing system includes a two-part design for overhead elements (heel and bars) that allows two (2) cartons to successfully be closed (or left open) independently in sequence.

In an example of operation, the fold-down bars arranged above the carton keep the carton lid closed as the minor-flap cleats are gently withdrawn. The hold-down bars are mounted using a lever mechanism that provides consistent downwards pressure based on carton size and carton motion. A roller in the heel allows uneven-shape lids to be successfully closed (for instance cardboard lids with indented portions).

The carton lid closing system may also include a plurality of lid flipper fingers that can actuate up/down to close the carton or leave it open. As an example, because the majority of cartons with embedded lids are closed the lid flipper fingers may be spring-loaded to the ‘close’ position, reducing the power consumption for the two solenoids and increasing their expected lifespan.

As such, in general, the lid flipper fingers may be spring-loaded, allowing flats and other non-closed or pre-closed carton types to pass over the top without requiring activation of the solenoid. In this example, the lid flipper fingers suit both 12-packs, 18-packs and 24-packs, including size variants such as double-six and jumbo cartons. In general, the relative geometry of the lid flipper fingers, heel and hold-down bars set, generates consistent performance. The hold-down bars and heel can be independently latched into a disengaged position to avoid the potential for damage to eggs in non-closed cartons. The complete heel and hold-down bar assembly is removable for cleaning and access. It is appreciated that the design may be flexible to accommodate many cartons: 12-packs, 18-packs, 24-packs, 36-packs, flats, and foam, PET, fiber and other carton materials. The wide hold-down bars can reduce local pressure on the carton lid, as well as provide pressure over a wide area to accommodate many possible carton latch positions. The spacing of conveyor cleats and hold-down bars may accommodate many possible (all known) latch positions.

In an embodiment, the closer conveyor may move independently of the lasing conveyor, providing more flexibility for motion profiles. The cleats on the closer conveyor are designed to function successfully with all carton types. The hold-down bars apply gentle friction resistance to forwards motion to hold the cartons back against the cleats and generate tightly controlled motion of the carton. The transition to the second conveyor (or direct to the outfeed in some embodiments) may be timed to coincide with the withdrawal of the cleats from the tucker flap, with the hold-down bars keeping the lid closed and the cleats engaged during the transition.

In another embodiment, the second closer conveyor is mechanically coupled to the first, to eliminate the need for a second motor and controller. The timing between the cleats of the two conveyors may be set for smooth transition. Additionally, in another embodiment, the second closer conveyor can be used for a carton printing process known in the art.

It will be understood that various aspects or details of the invention may be changed without departing from the scope of the invention. It is not exhaustive and does not limit the claimed inventions to the precise form disclosed. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation. Modifications and variations are possible in light of the above description or may be acquired from practicing the invention. The claims and their equivalents define the scope of the invention.

Claims

1. A system for closing carton lids having a first end and a second end, operable to receive an object at the first end of the carton lid closing system and to close a lid of the object, the carton lid closing system comprising:

a carton lid flipper having a first end and a second end, the carton lid flipper operable to contact a lid of an object at a point between and including the first end and second end of the carton lid flipper, wherein the contact by the carton lid flipper is operable to at least partially close the lid of the object; and

a carton lid closing heel having a first end and a second end, the carton lid closing heel operable to contact the lid of the object at a point between and including the first end and second end of the carton lid closing heel, wherein the contact by the carton lid closing heel is operable to more fully close the lid of the object.

2. The system of claim 1, further comprising a roller attached to the second end of the carton closing heel, the roller operable to rotate along an axis parallel to a plane defined by a top surface of the lid.

3. The system of claim 1, further comprising a carton lid hold-down bar operable to contact the lid of the object after the lid has been more fully closed by the carton lid closing heel.

4. The carton lid closing system of claim 1, further comprising a carton lid flipper activation mechanism attached to the carton lid flipper operable to move the carton lid flipper into a first position in which the carton lid flipper can contact the lid of the carton and into a second position in which the carton lid flipper cannot contact the lid of the carton.

5. The carton lid closing system of claim 4, wherein the carton lid flipper activation mechanism is a solenoid attached to the first end of the carton lid flipper.

6. The carton lid closing system of claim 5, further comprising a spring attached to the first carton lid flipper operable to restore the carton lid flipper to a default position when the solenoid is inactive.

7. A flap bending system, having a first end and a second end, operable to receive an object at the first end of the system and to bend the flap of an object, the flap bending system comprising:

a flap bending system conveyor defining a flap bending system conveyor movement path and operable to move the object form the first end to the second end of the flap bending system at a flap bending system conveyor speed;

a hold-back pin having a first end and a second end, the hold-back pin operable to move at a hold-back pin speed along the flap bending system conveyor movement path and to contact the object, wherein the contact by the hold-back pin is operable to inhibit the object from moving along the flap bending system conveyor at greater than the hold-back pin speed; and

a flap bending arm having a first end and a second end, the flap bending arm operable to move at a flap bending speed along the flap bending system conveyor movement path and to contact a flap of the object, wherein the contact by the flap bending arm is operable to bend the flap of an object.

8. The system of claim 7, further comprising a carton disengagement system comprising:

a ramp section having a first end, a second end, and a ramp angle;

a disengaging section having a first end, a second end, and a disengagement angle;

the first end of the disengaging section attached to the second end of the ramping section; and

the ramp angle being different from the disengagement angle, wherein the difference in angle is operable to disengage the egg carton from the flap bending arm.

9. The system of claim 7, where the ramp angle is greater than the disengagement angle.

10. The system of claim 7, where the hold-back pin speed is equivalent to the flap bending arm speed.

11. The system of claim 7, where the hold-back pin speed and the flap bending arm speed are equivalent to the flap bending system conveyor speed.

12. The system of claim 7, where the flap bending arm is operable to rotate to contact the flap of an object.

13. The system of claim 7, further comprising a hold-back pin activation mechanism operable to move the hold-back pin into a position capable of contacting the object, the contact by the hold-back pin configured to inhibit the object from moving along the flap bending system conveyor at a greater speed than the hold-back pin speed.

14. The system of claim 7, further comprising a flap bending arm activation mechanism configured to move the flap bending arm into a position capable of contacting the flap of an object, the contact by the flap bending arm configured to bend the flap of the object.

15. The system of claim 7, wherein the flap bending arm activation mechanism is a flap bending arm guide shaft track defining a flap bending arm guide shaft track movement path, the flap bending arm attached to the flap bending arm guide shaft track and capable of moving along the flap bending arm guide shaft track, wherein the flap bending arm is configured to activate through movement of the flap bending arm along the flap bending arm guide shaft track movement path.

16. The system of claim 7, further comprising a hold-back pin activation mechanism configured to move the hold-back pin into a position capable of contacting the object, the contact by the hold-back pin configured to inhibit the object from moving along the flap bending system conveyor at greater than the hold-back pin speed, and

a flap bending arm activation mechanism configured to move the flap bending arm into a position capable of contacting the flap of an object, the contact by the flap bending arm configured to bend the flap of the object.

17. The system of claim 7, wherein the hold-back pin activation mechanism is a hold-back pin guide shaft track defining a hold-back pin guide shaft track movement path, the hold-back pin attached to the hold-back pin guide shaft track and capable of moving along the holdback pin guide shaft track, wherein the hold-back pin is configured to activate through movement of the hold-back pin along the hold-back pin guide shaft track movement path, and

wherein the flap bending arm activation mechanism is a flap bending arm guide shaft track defining a flap bending arm guide shaft track movement path, the flap bending arm attached to the flap bending arm guide shaft track and capable of moving along the flap bending arm guide shaft track, wherein the flap bending arm is configured to activate through movement of the flap bending arm along the flap bending arm guide shaft track movement path.

18. The system of claim 7, wherein the hold-back pin guide shaft track and the flap bending arm guide shaft track are concentric.

The system of claim 7, further comprising a carton disengagement system comprising: a ramping section having a first end, a second end, and a ramp angle; a disengaging section having first end, a second end, and a disengagement angle; the first end of the disengaging section attached to the second end of the ramping section; and the ramp angle being different from the disengagement angle, wherein the change in angle is configured to disengage the egg carton from the at least one flap closing arm.

19. A method of bending the flap of an object, the method comprising:

moving the object along a flap bending system movement path defined by a flap bending system conveyor;

preventing the object from exceeding a hold-back pin speed by contacting the surface of the object with a hold-back pin moving at the hold-back pin speed along the flap bending system conveyor movement path; and

bending the flap of the object by contacting the flap of the object with a flap bending arm moving at a flap bending arm speed along the flap bending system conveyor movement path.

20. The method of claim 19, further comprising the steps of disengaging the flap bending arm by moving the object through a ramp section at a different angle from the previous section and wherein the bending of the flap of the object is performed by rotating the flap bending arm.