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System and method for packaging article layers

System and method for packaging article layers description/claims

The present invention is directed to a system and method for packaging article layers, and specifically to a system and method for packaging article layers for articles having substantially non-uniform geometries.

When large numbers of stackable articles must be transported in large quantities to another location, especially when the article is small, the article may be packaged in a container to protect the article during shipping of the container. Alternately, to reduce the amount of handling required, the articles may be arranged in a tight grouping, or array of articles. Each array of articles can form a layer of articles that can be stacked on a pallet having a footprint which can be accommodated by freight hauling compartments, e.g., for truck, rail, sea or air vessels.

Palletizing articles is becoming increasingly automated in manufacturing facilities, wherein articles are moved via a conveyor, which articles are manipulated by robots onto pallets. Such processing may work well if the articles are inherently stable, i.e., having a broad base footprint and low center of gravity, which articles being resistant to tipping. However, there can be difficulties associated with elongated articles having a small base footprint, as such articles are susceptible to tipping. Moreover, problems associated with tipping articles are significantly increased when the articles are especially lightweight, such as empty articles, that are shipped to locations for filling the articles with product.

Assembly of article arrays is currently performed using conventional bulk palletizers. Most conventional bulk palletizers build the complete article array or bulk array or article layer and then move or “sweep” the completed array layer or bulk array into position onto the pallet. Palletizing robots are also used, but most palletizing robots also move the completed article layer or bulk array onto the pallet. Alternately, the palletizing robots construct an article array by placing individual rows of articles to form the array. However, the previously discussed problems associated with article tipping have not been resolved. In addition, the conventional palletizer constructions are difficult to be quickly and cost effectively re-configured to accommodate different article designs or array patterns.

As shown in FIG. 1, articles 12 having non-uniform geometries pose additional challenges, as they are prone to tipping, even when supported along the collective periphery of the article array or layer. Currently, empty articles having non-uniform geometry are typically transported to packaging facilities using two techniques. In a first technique, the articles are loosely loaded en masse into a container having a liner. This technique results in a random, inconsistent and inefficient arrangement of the articles in the container. With the other technique, a rectangular container to be filled with articles is disposed at an angle from a horizontal plane. The container, either manually or with aid of a robotic arm, is loaded with rows of articles that are alternatively inverted, providing a consistent, improved container arrangement. However, both approaches have the disadvantage of having to dispose of both the container and the container liner.

What is needed is an apparatus and method that effectively package articles having non-uniform geometries while substantially eliminating the possibility of articles tipping during packaging, that also eliminates the need for both a container and container liner for article layers and for palletized article layers.

The present invention relates to a method for packaging articles. The steps include arranging a plurality of articles having a substantially non-uniform geometry within a first collection area and transporting the plurality of articles from the first collection area to a consolidation area for constructing an article layer. The method further includes laterally supporting the periphery of the plurality of articles arranged within the consolidation area to substantially prevent tipping of the plurality of articles and arranging a subsequent plurality of articles within the first collection area. The method further includes transporting the subsequent plurality of articles from the first collection area to the consolidation area adjacent the plurality of arranged articles, the periphery of the plurality of arranged articles being continuously laterally supported while the subsequent plurality of articles is being arranged. The orientation of the subsequent plurality of articles is different than the orientation of the plurality of arranged articles. Upon the arrangement of the subsequent plurality of articles, the periphery of the plurality of arranged and subsequently arranged articles is laterally supported. The method further includes repeating the arranging and transporting steps for subsequent plurality of articles until the article layer is constructed and substantially enclosing the article layer in a layer of resilient material substantially maintaining the arrangement of the article layer.

The present invention further relates to a system for packaging articles including a first collection area for receiving and arranging a plurality of articles having a substantially non-uniform geometry. A transport device is included and a consolidation area for constructing an article layer, each article layer constructed from the plurality of arranged articles transported from the first collection area by the transport device. The consolidation area includes a stabilizer providing substantially continuous lateral support along the periphery of arranged articles of the article layer being constructed to substantially prevent tipping of the plurality of arranged articles. A portion of the arranged articles transported by the transport device is oriented differently from the other arranged articles.

An advantage of the present invention is that article layers of articles having non-uniform geometry are substantially prevented from tipping.

A further advantage of the present invention is that article layers of articles having non-uniform geometry can be enclosed in a resilient layer of material, not requiring a container.

A yet further advantage of the present invention is that the arrangement of the articles of an article layer is substantially similar to the arrangement of an enclosed article layer.

A still further advantage of the present invention is that enclosed article layers of articles having non-uniform geometry can be arranged on a pallet.

The present invention encloses article layers of articles having non-uniform geometry without requiring a container.

Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

FIG. 1 is an elevation view of articles having non-uniform geometries for use with the present disclosure.

FIG. 2 is a schematic of an embodiment of an article packaging system of the present disclosure.

• Provisional Patent
• Utility Patent

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