CA2011898A1

CA2011898A1 - Apparatus for forming a bulk package

Info

Publication number: CA2011898A1
Application number: CA002011898A
Authority: CA
Inventors: Joseph E. Geyser; Nestor Kozbur
Original assignee: RIVER (JAMES) Corp
Current assignee: RIVER (JAMES) Corp
Priority date: 1989-06-05
Filing date: 1990-03-09
Publication date: 1990-12-05
Also published as: US4897980A

Abstract

ABSTRACT OF THE DISCLOSURE

Apparatus for forming a bulk package and including bottom tray placement means for placing a bottom tray on a support, stacking means for stacking layers of objects on the bottom tray, top cap positioning means for positioning a top cap over the upper-most layer of stacked objects, and post member positioning means for positioning post members at preselected spaced locations between the bottom tray and top cap.

Description

;~ ~

Attorney Docket No. 3amRiver~

APPARATUS FOR_FORMING A BULK PACKAGE

~C~N CAL FIE~D
The present invention relates ~o an apparatu~ ~or forming a bulk package. More specifically, the apparatus is adapted to form a bulk package including object~, such as individual packages, stacked in layers with each layer comprising a plurality of the objects disposed ~n rows. The bulk package also includes a bottom tray disposed under the lower-most layer, a top cap disposed over the upper-most layer and a plurality o~
elon~ated post members extending between the bottom tray and the top cap.
:.
BACKGROUND ART
It is known in the prior art to fo~m bulk paokages oP
ob;ects stacked in layers. In particular~ it is known to ~or~
multi-tiered or multi-layered bulk packages of individual packages whereby the individual package~ may be shipped and stored in bulk prior to separate sale thereo~ to a customer.
Obviously, it is advantageous to hold costs of bulk packaging to a minimum while providing a bulk package which has the regui~ite strength requirements. Such considerations bec~me especially signi~icant when the indlvidual ob;ects to be bulk packaged for shipment and 5torage are themselves relatively inexpensive. Examples of this l~tter type oP object are ~, .

`, ' ' , , .

:

2;~
individual wrapped packages o~ one or more roll paper products.
It is also desirable to minimize the we~ght o~ the bulk package itself to hold down transport costs.
A number of bulk package arrangements haYe been devised for transporting and storing a large number of individual packages of roll paper products such as paper towels and toilet tissue. One such bulk package found to be particularly suitable ~or products of this nature is a bulk package employing a bottom tray disposed under the lower-most layer o~ a plurality o~ layers of individual packages, a top cap disposed over the upper-most layer, and a plurality of elongated post members extending between the bottom tray and the top cap. This entire assembly ls ~: conventionally over-wrapped with plastic film for subsequent shipping and storage.
It has b~en conventional practice up to the present to manually construct a bulk package of the type just described.
Obviously, such a procedure is labor intensive and expensive.
It is therefore an object o~ the present invention to provide an apparatus ~or forminy a bulk package of the a~ore-described type. The preferred form of apparatu~ disclosed hereinis specifically adapted to form a bulk package ~ncluding a plurality of individual packages of roll towels or the like. Not only does the apparatus efficiently and quickly form such a bulk package, it is capable o~ forming bulk packages of d~fferent sizes and from di~ferent sized lndiv~dual packages.

DISCLOSURE O~F INVENTIO~I
Apparatus constructed in accordance with the teaching~
of the present invention performs a ~ariety o~ operations culminating in the formation of a bulk package including objects, such as roll paper towel packages, stacked in layers with each layer comprising a plurality of objects disposed in rows.
The apparatus includes bottom tray placement means ~or placing a bottom tray on a support. Stacking means is then employed ~or stacking the layers of objects on the bottom tray.
After the objects have been stacked to a desired height, top cap positioning means positions a kop cap over the upper-most layer of objects. Post member positioning means is then utiliæed to position post members at preselected spaced locations between the bottom tray and the top cap.
In the particular embodimsnt of the invention disclosed herein, the bottom tray and top cap each include a central panel and flaps disposed at least partially about the periphery thereof, and the apparatus additionally compxises flap manipulating means for engaging the cap and tray flaps, ~olding them relative to the panels, and bringing the ~lapæ into engagement with the post members. The tray flaps ~nd cap flaps are secured together by adhe5ive and serve to maintain the post me~bers at the preselected spaced locations.
Other ~eatures, advantages and objects of the prssent.
2S invention will become apparent with reference to the following detailed desaription and accompanying drawings.
.

.

2 ~

-BRIEF DESCRIPrrION OF DRAWINGS
Fig. 1 is a perspective view of a ~ulk package assembled by apparatus con5tructed in accordancs with the teachings of the present invention;
. Fig. lA is an exploded perspective view of the elements of the bulk package o~ Fig. 1 exclusive of the individual packages;
. Fig. 2 is a diagrammatic side view of a preferred embodiment of ~pparatus constructed in accordance with the teachings of the pres~ent in~ention;
Fig. 3 is a diagrammatic end view o~ the apparatus and illustrating selected components thereof;
Fig. 4 is a diagrammatic plan view illustrating 6elected components of the apparatus;
Figs. 5, 5A are diagrammatic side views Or a preselected portion of spacer pad applicator means during subsequent stages of the operation thereof when applying a spacer pad to the bulk package top cap;
Fig. 6 is a diagrammatic perspective view of cap flap .: manipulating means;
Fig. 6A is a diagrammatic perspective view of tray flap manipulating means;
Fig. 7 is a schematic presentation illustrating an apparatus adjust O ility feature; and .

, : . .

J

Fig. 8 is a diagrammatic slde ~iew oP selected components of the apparatus post member placement mechanism.

BEST MODE E'OR CARRYI~G OUT THE INVENTION
Referring now to Fig. 1, a bulk package o~ the type formed by the apparatus of the present invention is illu~trated.
The bulX package is designated generally by re~erence numeral 10 and includes objects 12 skacked in layers with each layer comprising a plurality of the objects disposed in rows. In Fig~ l the ob;ects 12 are individual packages, each o~ which contains a plurality of paper towels. For example, each package 12 might ~ccommodate anywhere from three roll~ to twelYe rolls of toweling or moxe. In the bulk package configuration illustrated, the individual packages 12 are disposed in nine rows in one direction and three rows in another direction. As will be seen below, the apparatus of the present invention incorporates an ad~ustability feature which enabl~s the apparatus to ba adjusted to handle a variety o individual package sizes and configurations.
Referring now also to Fig. 2, the bulk package 10 also includes a bottom tray 14 including a central tray panel 16 and tray ~laps 18, 20, 22, and 24. Opposed tray flap~ 20, 24 each include a central tray flap portion 26 and end tray ~lap portions 28 hingedly onnected to opposed ends o~ the central trap ~lap portion 26.

(8 In the completed bUlk packag~ 10 hottom tray 1~ ls disposed under the lower-most layer o~ packages 12. It will be appreciated that the outer periphery of the stacked packaye~ 12 corresponds generall~ to the shape o~ the tray panel 16. In the embodiment shown in F~g. 1, there are ~ive layer~ of individua~
packages 12~ As wil:L be seen below, however, the apparatu~ of the present invention is adapted to form bulk packages o~ various : layer heights.
Disposed between each of the layers is a tier sheet 30 of paperboard or the like which has an outer periphery generally conforming in shape to that of tray panel 16. A top cap 32 ~s .
disposed over the upper-most layer of individual package~ or objects 12~ The top cap 32 is also suitably constructed o~
corrugated paperboard or the liXe, as is the previously described bottom tray 14.
~ op cap 32 lncludes a central cap panal 34 and cap flaps 36, 38, 40, and 42 disposed at least partially about the periphery of the cap panel. Opposed cap ~laps 38, 40 each includes a central cap flap portion 44 and end cap ~lap portions 46 hingedly connected to opposed ends of the central cap flap portion. Thus, it is readily apparent that the bottom tray 14 and top cap 32 are identical in construction. This is advantageous since only one blank style need be utilized to function as either the bottom tray or top cap.
In the assembled bulk package lO, the tray ~laps o~
bottom tray 14 and the cap flaps of the top cap 32 ar~ ~olded and . . .

: ' . .

(8 disposed at 90 degree angles with respect to the bottom tray and cap flap. As will be described ln grsater detail below, the cap flaps are secured together by adhesive ko mai~tain the configuration 111ustrated in Fig. 1. Similarly, the tray ~lap~
are secured together by adhesive to maintain their respective positions shown in Fig. 1.
Yet another component of the bulk package 10 is a plurality of elongated post members 48 extending between the bottom tray and the top cap. As can clearly be seen, the post members each have a generally V-shaped cross sectio~. The post members are pre~erably constructed of a relatively rigid, strong;
yet inexpensive, material such as f iberboard . In the assembled bulk pacXage 10 the post members are located at the bulk package corners with the open end of the V-shape oriented toward the individual packages 12. The tray flaps and the cap flaps are in angagement with the post members. Thus, the upper ends of the post members are ~rictionally engaged and maintained in position by the packages 12 located at the corners and the cap flaps.
Similarly, the lower ends of the post me~bers are frictionally engaged and maintained in position by the packages 12 located at the corners and the tray flaps.
Yet another component of the bulk package 10 is a plurality of spacer pads 50 which are secured to the ~op of top cap panel 34 by adhesive. Each spacer pad may be constructed o~
any suitable material such as multi-laminate, corrugated paperboard. The spacer pads are essentially block-shaped and have sufficienk heighk and clearance there~etween to allow Por fork lift passage. 5uch an arxangement will enable bulk packages 10 to be stacked one upon the another ~or storage and shipment.
The apparatus for forming the bulk package 10 will now be described. Referring now specifically to Fig. 2, the apparatus for forming the bulk package includes a fra~ework 52.
Disposed on framework 52 are a plurality o~ ~ack screws 56 which serve to support a stack of blanks 58 which are all of ldentical construction and can be used interchangeably as 0ither bottsm trays 14 or top caps 32. As stated above, the bottom tray and top cap of the bulk package 10 shown in Figs. 1 and 2 are of identical construction.
Disposed above the stack of blanks 58 ls blank . 15 placement mechanism 60 which includes a pneumatic cylinder 62 and an arm 64 fixably attached to and moveable with a piston within cylinder 62 in a conventional manner. Dependent ~rom ths fre~
end of arm 64 is a second pneumatic cylinder 66 having a piston arm 68 movably relative therPto. It wlll be appreciated that arm 64 is reciprocatably moveable ~n a horizontal plana while arm 68 is reciprocatably moveable in a vertical plane, as viewed in Fig. 2.
: Connected to the distal end of piston arm 68 is a vacuum cup support 70 having a plurality of vacuum cups 72 dependent therefrom. The blank placement mechanism 60 just described functions to move blanks 58 seriatim from the stack of ` ~ :2~8~
blanks, transport the re~oved blank to khe right, as viewed i~
Fig. 2, and place the removed blank over a support in the form of an endless belt conveyer 74. 'rhat is, the vacuum cup suppork 70 is moved down from the position illustrated in Fig. 2 until the vacuum cups 72 contact the upper-most of blanks 58. At this stage, vacuum is formed at the cups and the vacuum cups retain the top-most blanX when the support 70 is retracted upwardly.
The pneumatic cylinder 62 and arm 64 then cooperate to move the suspended blank to the right as viewed in Fig. 2 until the blank is disposed over the conveyer 74.
The jack screws 56 are preferably o~ the commercially available type which will automatically raise the rest of the stack of blanXs upwardly a distance corresponding to a single blank thickness when a blank has been removed. Blank placement mechanisms and jack screw devices are well known par se in the prior art; thus, it is not deemed necessary to describe these in great detail.
In Fig. 2, the belt conveyer 74 is mounted on a frame 76 which comprises the upper portion o~ a scissors llft or elevator 78 which is illustrated diagrammatically and may be of any suitable conventional construction. The ~cissors lift 78, when actuated, will result in eithar upward or downward movement of frame 76 and hence conveyer 74 as shown by the double headed arrow disposed adjacent to the depiction of the scissors lirt 78.
Fig. 2 shows a partially asse~bled bulk package 10 disposed upon the support provided by the belt conveyer 74, such 3~
partially completed bulk packag~ including a bottom tray 14, paper towel packages 12 stacked in layers (four layers in the illustrat d configuration), and a top cap 32.
Formatlon o~ the bulk package commences With placement of the bottom tray 14 on belt conveyer 74 by blank placemént machanism 60. This occurs with the scissors lift 78 in partially extended position, that is, with the upper run of belt conveyer 74 disposed at about the same location top cap 32 occupies in Fig. 2. After the bottom tray 14 is posltioned o~
the belt conveyer 74, the scissors li~t 78 extends even furkher so that the bottom tray 14 is disposed ad~acent to and generally in line with individual package conveyer 80 which may be of any suitable construction. Package conveyer 80 is part of a mechanism adapted to assemble a layer of paper towel packages 120 Devices of this nature are well ~nown in the art and will not be described in detail. Suffice it to say that indlvidual package conveyer 80 is in the form of a shuttle plate which moves ~rom its position illustrated in Fig. 2 to the right, as viewed in that figure, to a location above scissors llft 780 When the shuttle plate ~oves back to its illu~trated position, a hydraulically operated stop m~mber 82 moves *rom the illustrated solid line position to the dash line position shown in Fig. 2 to prevent the paper towel packages 12 from returning also. In other words, the paper towel packages 12 are retained.
in fixed position to the right of stop member 82 while the conveyer or shuttle plate 80 moves back to the left and is 2~ $
withdrawn from underneath the packages 12. A pu~her device 84, which is pre~erably pneumatically actuated, coop2rates with a feed conveyer ~6 to again form a layer o~ paper towel package~ 12 on shuttle plate 80. Mechanisms of this general t~pe are also well known in the packaging art and any suitable arrangemént may be provided to assemble a desired number of paper towel packages 12 in any desired configuration or "footprintl' upon the shuttle plate 80.
It will be appreciated that when shuttle plate 80 retracts to the left as viewed in Fig. 2, the first layer o~
paper towel packages 12 will be disposed on tray panel 16 of bottom tray 14. After this has b~en accomplished, the scissors lift 78 will retract a distance generally corresponding to the height of a paper towel package 12. The just described cycle continues until a desired number o~ individual package layers are stacked on the bottom tray.
It is pre~erable that tier sheet~ 30 be positioned between each layer of packages 12 to provide bulk package stability and strangth. Any suitable device may be utilized to place the tier sheets on a layer prior to placement of a subse~uent individual package layer. For example, the tier sheets may be positioned in place by a mechanism similar to blank placemen~ mechanism 60. Fig~ 4 provides a schematic illustratior.
of a tier heet 30 being transported by a pusher arm 88 which ~
25 part o~ an overall tier sheet placement mechanism, the remainder ` 11 .

o~ which, in the inkerest o~ simplicity, ha~ not he~n illustrated.
~ fter the upper-most layer o~ paper towel packages has been stacked, the sclssors li~t 78 retracts to the position shown in Fig. 2. The blank placement mechanlsm 60 then operakes to position the top cap 32 over the upper-most layer of packages 12 precisaly in the manner it ~unctioned during placement o~ the bottom tray 14.
At this stage of the operation the bottom tray 14 and top cap 32 have a generally planar con~iguration; that is, the tray ~laps o~ the bottom tray are in alignment with the tray panel and the cap ~laps o~ the top cap are in alignment with the cap panel. The tray flaps and cap ~laps therefore project beyond the stack of paper towel packages 12.
The next step of the operation o~ the apparatus is to transport the partially assembled bulk package 10 to the right as viewed in Fig. 2. This is accomplished by actuating belt conveyer 74 50 that the upper run thereof moves toward the right.
Substantially simultaneously therewith a second belt conveyer 90 is actuated so that its belt rotates in a clockwise directlon as viewed in Fig~ 2. An intermediate belt conveyer (not shown) can be disposed between belt conveyers 74 and 90 to insure that there is a æmooth transition therebetween o~ the partially assembled bulk package 10. Such intermediate conveyer has not been illustrated in the interest of simplicity and, in ~actt may not be necessary i~ belt conveyers 74 and 90 are close enough to prevent tipping or other undue movemsnt o~ the bulk package 10 as ~t is being conveyed.
As perhaps best seen with re~erence to Figs~ 2 and 3, the partially assembled bulk package 10 during conveyance thereo~
between belt conveyer 74 and belt conveyer 90 passes by a plurality o~ spray nozzles 92 which are adapted to spray adhesive onto the bottom tray 14 and top cap 32. ~ore particularly, the spray nozzles 92 are disposed in two tiers, with some o~ th~
nozzles applying adhesive to predetermined portion~ 94 (see Fig. lA~ o~ the tray flaps and cap flap predetermined portions 96. In addition, some o~ the spray nozzles 92 are adapted to apply adhesive to the cap panel 34 at predetermined areas 98 thsreof~ Pre~erably, the spray nozzles 92 are mounted in such a manner as to be readily adjustable whereby the spray nozzles can be moved to adapt to bulk packages 10 o~ different dimensions, as for example, when the bulk package is forme~ fro~
individual packages or o~jects 12 of di~ferent dimension or number. All nozzles are pointed downwardly to render adhesive application more effective. Any suitable control mechanism such as a well-known photo eye and switch arrangement may be employed to actuate and deactuate the spray nozzles.
~ s may be seen in Figs. 3 and 4, belt conveyer 90 comprises two-spaced belts 102, 104 which are separately ~ournaled on rollers supported by two lndependent conveyer frames 106, 108. Preferably, each of these convey~r frames i~
adjustable whereby they may be moved toward or away from one ..

.

'$

another on mounting pads 110, 112. A track and roller arrangement ~not shown) may be utilized to ~acilitate relativ~
adjustment o~ the conveyer frames.
When the partially assembled bulX package 10 arrivQis at the position ~hown at the right o~ Fig. 2, the conveyer 90 i~tops.
For example, the conveyer may be associated with ~n electric eye (not shown) which senses the arrival o~ the partially assembled bulk package at the desired location. The partially assembled bulk package 10 is ~ow in position to have a variety o~
operations performed thereon to complete assembly thereo~.
In the right hand position illustrated in Fig. 2, the partially assembled bulk package 10 is located between 4 poist member positioning devices 114. The post member positioning devices are of identical sonstruction and each is opera~vely associated with a corner of the bulk package ~ormed by intersecting sides thereof. The post member posltioning~
devices 114 each include magazine structure llC adapted to ~old a plurality of post members. One such magazine structure ~16 i~
illustrated in Fig. 8. Each magazine structure includeis two separate open-topped holders 118, 120 disposed side by side, with each holder having side walls and a bottom wall upon which is stacked a plurality o~ post members 48. Each holder is attached to a threaded element 122 selectively moveable in an up-and-down fashion by an associated electrical jack screw motor 124 mounted on mounting member 126. Mounting member 126 is selectively . ~
moveable between the solid line position shown in Fig. 8 to the 14 i ~i !io;, , ~, ~`
8 ~ 3 phantom line po~ition illustrated thereln l~y a prlme mover which may, for example, be a hydraulic cylinder 128.
It will be appreciated that the ~ack screw motors 124 are operatively associated with any suitable conventional control - 5 means to automatically ra~ se a stack of post members 48 the thickness of a post member ~ach time a top-most post member i removed from the stack in a manner which will be described below.
The phantom line representation presented in Fig. 8 shows a partially depleted stack and in such condition the motor 124 has caused its associated threaded element 122 to move upwardly along with the holder bottom support wall past th~ holder sidé wa~ls which are fixed in position by any known expedient.
The post member positioning device 114 also includes means for r~moving a post member from the afore descxibed magazine structure. ~his post member removal means is generally designated by re~erence numeral 130 and includss a pick-up element 132 moveable between a first position whereat thP`pick-up element engages the post member at the magazine structure ~the .
position illustrated in Fig. 8) to a second position spaced from ` 20 the magazine structure. The pick-up element 132 comprise~ a pair o~ spaced, pivoted pick-up arms 134 and a vacuu~ cup assembly 136 pivotally mounted on each pick-up arm 134 on a pivot 138.
Each vacuum cup a~sembly includes a plurality of vacuum cups 140 which are angled as perhaps best seen in Fig. 8 50 that .,, ,1'. . :., ~ .
~5 the cups engage the diverging legs of the generally Y-shaped post members. The pivot connection 138 between vaFuum cup . :

2~1~89~
asse~blies 136 and pick-up a~ms 134 ~acilitate~ relativ~
posltioning o~ the vacullm cups 1~0 to accommod~te any chang~ in positioning or configuration o~ the post ~ember~ at the top o~ a stack. The vacuum cups 140 are operatively associa~ed wi~h any suitable vacuum source through any suitable arrangement whereby a vacuum may be selectively applied to the top-most engaged post membar and cause samP to adhere to the vacuum cups.
As can perhaps best be seen with reference to Fig~ 8, the end of pick-up arms 134 remote from vacuum cup assemblies 136 lo is operatively associated with a gear 142 having teeth engagi~g teeth of a rotatable drive member 144. Me~ber 144 is rotated in a reciprocal mannex by a prime mover which may, for example, be a hydraulic cylinder 146. Extension of the arm of the hydraulic cylinder 136 will cause counter cloek-wise pivoting o~ pick-up arms 134. Retraction of the hydraulic cylinder device will cause the pick-up arms to rotate in clock-wise fashion about the end thereof remote from vacuum cup assemblies 136.
When the pick-up axms 134 are rotat2d clock-wise as illustrated ~y th~ arrow in Fiy. 8, the vacuum cups 140, having had vacuum applied thereto, serve to lift from the stack o~ po~t members disposed therebelow the top-most post member which of course is engaged at spaced locations thereon by the vacuum cups.
The pick-up element 132 moves about a ~ixed pivot and the holders 118, 120 ~ay be selectively positioned under the vacuum cup assemblies 136 merely by actuating prime mover 128.
If desired, the holders 118, 120 may contai~ post member 4a of , .

: the same length. Alternakively, where di~erent-~ized bulk packages are being formed, post members o~ di~erent length3 may be held in each of the holders with the prime mover 128 operating to bring the proper holder into registry with ~he vacuum ~up assemblies 136 depending upon how many tiers or layers o~ paper towel packages or other ob;ects are to be in the bulX package.
The rotating pick-up arms 134 b~ing the post member 148 retained by vacuum cups 140 to a second position spaced ~rom both the magazine structure and the object~ 12 in ~he partially assembled bulk package. Located at sa~d second location is means for placing the removed post member into engage~ent with ob~ects located at one of the corners of the bulk package. ~ore specifically, such means for placing the removed post member into . engagement with ob;ects located at one of the corners comprises a .~ 15 transport element 150.
. The construction and operation of ths transport element 150 of each post member positioning device 114 is best illustrated in Figs. 4 and 5. In actual operation, all o~ the post member positioning de~ices function in ~ubstantial uni~on and the transport elements 150 thereof also per~onm their appointed tasks at generally the sa~a time. However, to more clearly disclose the transport element, Figs. 3 and 4 illustrate the transport elements on the right-hand side o~ those figures at one stage of their operation while the transport elements 114 on the left-hand sides of Figs. 3 and 4 are illustrated in a subsequent stage of their operation.

~ .
.~

.

Quite simply, ik is the ~ask o~ each transpor~
element 150 to recelve a post member ~rom it~ associated pick-up .- element 132, orie~t the post membex in a vertical orienkation and place the vertical post member into engagemenk with paper tow~l packages or other ob;ects 12 of the bulk package ~t the corners of the bulk pacXage.
Each transport element 150 includes a primaxy transport arm 152 and an auxiliary transport arm 154. Primary transport arm 150 is pivotally mounted a~out pivot 156 and air cylinder 158 selectively move~ the primary transport arm 152 from the horizontal position illustrated on the right-hand side o~ Fig. 3 to the vertical position illustrated on the le~t-hand sid~ o~
Fi~. 3.
The auxiliary transport arm 154 is pivotally attached as by means of hinge 160 to the distal end o~ primaxy transport arm 152. The distal end of auxiliary transport arm 154 includes a cradle element 162, the cradle element lncluding interconnected diverging sides generally corresponding to the configuration o~
the V-shaped cross section of the post members.
During the initlal stage o~ operation o~ transport element 150, the auxiliary transport arm is also di~posed generally horizontally. The relationship betw~en the pick-up element 132 and the transport element 150 is such that when the pick-up arms 134 rotate from the aforesaid ~irs~ pos$tion to th8 second pos~tion the pick-up arms and vacuum cup assemblies swing down past and clear the ends of auxiliary transport arm cradl~

18 .
.

20~189g element 162 as perhaps best see~ in Fig~. 3 and 4~ Thi~ movement causes the post member ~upported by the vacuum cup assembliQ~ 136 to lodge in cradle 162. Suitable switching ~echan~m turn~ o~
; the vacuum to vacuum cups 140 and applies a vacuum to vacuu~
cups 164 operatively associated with the cradle element 16~.
Thus, the post member 48 is secured into position relative to the cradle element 162 by the vacuum.
A~ter this trans~er has been accomplished, the primary transpoxt arm and auxiliary transport arm are rai~ed to their respective ~ertical positions illustrated on the left hand side of Fig. 3 by their operatively associated air cylinder 158.
Referring now to Fig. 4, the left hand side of that figure illustrates tha positions assumed by the two adiacent transport elements 150 after the primary transport arm has baen raised to a vertical orientation. It wlll be seen that the distal end of the auxiliary transport arm 154 is initially spaced ~rom the adjacent bulk package corner. That ~; the auxiliary transport arm 154 occupies the solid line position illustrated at the le~t-hand side o~ Fig. 4.
2n A second prime mover means in the ~orm o~ an air cylinder 168 is actuated and the auxiliary transport arm 154 pivots to the dash line position. In the dash line position the distal end o~ the auxiliary transport arm urges ~he post membex 48 carried by the cxadle element 162 thereo~ against individual packages or objects 12 disposed at the adjacent bulk package corner. The auxiliary transport arms 154 o~ all o~ ~he , 19 .

. 2~89~
post member positioning devices 114 maintain the po8t memberg 48 in engagement with the corner packages during the next ~tep in the assembly of the completed bulk package which wlll now be described.
While the post members 48 are being held at the corners of the partially completed bulX package 10, a mechanism which will now be described operates to fold the tray flaps o~ the bottom tray and fold the cap flaps o~ the top cap so that such flaps occupy the positions shown in Fig. 1. It will be noted that in the as~emblad bulk pa~kage 10, th~ tray flap~ ars disposed over the lswer ends of the post members 48 and such lower ends are frictionally engaged between ad~acent tray flaps and the bottom tier of individual packages 12. Similarly, the upper ends of post members 48 are sandwiched bekween and frictionally engaged by adjacent cap flaps and the upper package tier or layer.
Re~erring now to Fig. 2, ~ounted ~or ~ovement relative to framework 52 above partially assembled bulk package 10, when the bulk package ~s centrally located betwePn the post member positioning devices 114, is a moveable frame 170 which is selectively moved up and down by a hydraulic cylinder device 172.
Mounted on frame 170 and moveable therewith are a plurality of spacer pad magazines which comprise spaced sidewalls 176 defining a guide-way ~or a stack of spacer pads 50. It will be appreciated that the magazines 174 correspond in nu~ber to the spacer pads 50 being applied to the cap panel 34 and that tha `

~ ' `` ~ 8 magazines 174 are located directly over the predet~r~ined areas 98 o adhesive previously sprayed onto ~h~ cap panel by spray nozzles 92.
Hingedly mounted on the outer-most side wall~ 176, i.e.
. ~ 5 the side walls generally in registry with the side wall~ o~ the bulk package 10, are cap ~lap engaging plates. The cap flap engaging plates are illustrated somewhat diagrammatically in Fig. 6. The cap flap engaging plates are identified by reference numerals 180, 182, 184, and 186. In the interest o~ simpllclty, only two such cap flap engaging plates, plates 180, 184, are shown ln Fig. 2. It will be noted with reference to Fig. 6 that cap flap engaging plates 180, 184 each include a central cap plate segment 190 and end cap plate segments 192 hingedly connected to the ends of, and moveable relative to, the respective central cap plate segments. Hydraulic cylinders 194 are disposed between each cap ~lap engaging plate and a spacer . pad magazine side wall and, when actuated, move the associated cap flap engaging plates ~rom a general horizontal disposition to a vertical one. ~his movement is illustrated and denoted by arrows in ~ig. 2.
The hydraulic cylinder device 172 lowers the ~rame and all o~ the equipment depending therefrom down and into close : proximity with top cap 32. At this point, the hydrauli~
cylinders 194 are actuated and the cap ~lap engaging plates pivotally moved down into a general vertical orientation. This serves to fold all of the cap flaps approximately 90 degrees ` 21 relative to the cap panel 34. A~ter thls ha~ been accompll~hed, a~r cylinders 196 disposed between central cap plate ~egment~ lgO
and their respective end cap plate segments 192 are actuated to fold the end cap flap portions 46 and place these portions into engagement with an adjacent cap flap. It will be appreclated that adhesive predetermined portions 96 axe disposed between the end cap ~lap portions and the adjacent cap flap whereby these components will be secured together.
Fig. 6A shows a similar arrangement for folding th~
tray ~laps. The tray flap manipulating means, in the interest of simplicity, has not been shown in Fig. 2, but lt is to be understood that the tray flap manipulating means illustrated diagrammatiaally in Fig. 6A is located in the vlcinity o~ belt conveyer 90.
The tray flap manipulating mean~ includes a plurality - of tray flap ~ngaging plates 202, 204, 206 and 208 to engage tray flaps 18, 20, 22 and 24. A hydraulia cylinder 212 iR associated with each tray flap engaging plate and adapted to push the tray flap engaging plate to an upright, generally ~ertical position.
20 This action obviously al~o bends the tray ~laps upwardly 80 that they are at right angles to t~e tray panel. Plate~ 202 and 206 each include a central tray plat~ segment 214 and end tray plate segments 216 hingedly connected to the ends o~ the central tray plate ~egment. Air cyllnder~ 218 are associated with the segments 214 and 216 to move the end tray plate segments at right angles relative to the central tray plate segments. This 2~

operation brings the ~nd tray ~lap portlon~ 28 into engagemen~
.
with an ad~acent tray ~lap. The adhe~ive previously applied ko predetermined portions 94 on the end tray ~lap portions 28 will : be disposed between the end tray flap portions and the ad~acent tray ~lap with which they are in partial registry. This will serve to maintain the lower ends of the post membsr~ 48 at their respective corners due to ~rictional engagement between the post members, ob;ects 12, and the tray flaps.
Re~erring once again to spacer pad magazines 174, Figs. 5 and 5A illustrate diagrammatically how spacer pads are applied to cap panel 34 when ~rame 170 i~ lowexed relatlve to the partially completed bulk package lo. ~he lower ends of spacar pad magazine side walls 76 approach but do not actually engage cap panel 34. The side walls 76 are in fa~t spaced from the cap panel 34 a distance slightly exceeding the thicknes of a spacer pad 50.
The staak o~ spacer pads 50 in each oP the spacer pad magazines 174 are freely slideably moveable therein but are prevented from falling out of the open bottom o~ the magazine by virtue of the ~act that the lower-most spacer pad 50 is frictionally en~aged between one of the side walls 176 and the moveable element of an air cylinder device 222. ~hen-tha moveable element i8 retracted, the lower~most pad will ~all to the position illustrated in Flg. 5A. That is, the lower-most spacer pad in the stack will engage the cap panel 34 at a predetermined area 98 to which adhes~ve has previously been ` 23 g applied. This adhesive will cause the pad to adhere to thQ cap panel. When thi~ has been accompllshed, the air oylinder . device 222 is again actuaked to clamp in place tha spac~r pad 50 restlng upon the spacer pad applied ko th~ cap panel.
A~ter a predetermined period o~ time su~fici~nt ~or the adhesive to bond the cap and tray ~laps has passed, th~ top cap and tray flap engaging plates are raturned to their respective initial positions and the hydxaulic cylinder devica 172 i3 actuatad to move ~rame 170 upwardly. The ~pacer pad~ 50 in the magazines 174 will not ~all out o~ the bottoms thereo~ becau~e of the action of air cylinder devices 222.
The bulk package 10 is now completely assembled.
Conveyer 90 is again actuated to move the bulk pacXage 10 to a desired downstream location~ Preferably, the bulk package 10 is covered with an outer wrap such as plastic ~ilm. Such expedient is well known, forms no part o~ the present invention, and is not illustrated.
One o~ the use~ul features of the pr~erred embodiment of apparatus constructed in accordance with the teachlngs o~ the present invention is its ability to ~orm bulk package~ o~
different sizes. For example, the dual magazine arrangement ror the post members already described allows the apparatus to form bulk packages of di~ering heights and tier numbers, Further adding to the versatility of the apparatus is the fact that the.
po~t member positioning device~ 114 may be moved relative to one another so that they will ~till operate to apply po~t m~mbers 48 ~ .

- - ` 2~L8~
to ~he bul~c packaye cornQrs regardles~ o~ thQ aut~r bulk packag~
size .
Flg. 7 illustrate~ diagramma~lcally the ~act that each post member positioning device 114 may be moved ~electlvely in either one o~ two directions, that is, either parallel to the run of conveyer 90 or at right angl~s thereto. As perhaps best illuRtrated in Fig. 4, each post member positioning device 114 is mounted on two relatively moveable mounting plates 230, 232.
Manually actuatable screw devices 234 and 236 pravide Por ad~ustment of the plates. It will be a~preciated ~hat ro~ation of screw devices 234 will move both mounting plate~ 230, ~32 ln a direction parallel to belts 102, 104 of conveyer 900 on thQ
other hand, rotation of screw devices 236 will ~ove mounting plates 232 relative to mounting plates 230 either toward or away from the conveyer 90. To facilitate such movement, a simple . track and wheel arrangement may be employed both between thQ
- mounting plates 230, 232 and between the ~ounting plate 230 and the floor supporting the apparatus. Fig. 8 illustrat~s a portion o~ such an arrangement.

Claims

1. Apparatus for forming a bulk package, said bulk package including objects stacked in layers with each layer comprising a plurality of said objects disposed in rows, a bottom tray disposed under the lower-most layer, a top cap disposed over the upper-most layer, and a plurality of elongated post members extending between the bottom tray and the top cap, said apparatus comprising, in combination:
bottom tray placement means for placing the bottom tray on a support;
stacking means for stacking said layers of objects on said bottom tray after placement of said bottom tray on said support;
top cap positioning means for positioning said top cap over the upper-most layer of objects after said stacking means has stacked said layers of objects; and post member positioning means for positioning post members at preselected spaced locations between said bottom tray and top cap.

2. The apparatus according to Claim 1 wherein said bottom tray includes a tray panel and tray flaps disposed at least partially about the periphery of said tray panel, said apparatus additionally comprising tray flap manipulating means for engaging said tray flaps, folding said tray flaps relative to said tray panel, and bringing said tray flaps into engagement with said post members.

3. The apparatus according to Claim 2 additionally comprising adhesive applicator means for applying adhesive to at least some of said tray flaps at predetermined portions thereof, said tray flap manipulating means operable during folding of said trap flaps to bring adjacent tray flaps together at said tray flap predetermined portions to secure said adjacent tray flaps together with said adhesive and maintain said post members at said preselected locations with said post members disposed between tray flaps and said objects.

4. The apparatus according to Claim 3 wherein said top cap includes a cap panel and cap flaps disposed at least partially about the periphery of said cap panel, said apparatus additionally comprising cap flap manipulating means for engaging said cap flaps, folding said cap flaps relative to said cap panel, and bringing said cap flaps into engagement with said post members.

5. The apparatus according to Claim 4 wherein said adhesive applicator means is adapted to apply adhesive to at least some of said cap flaps at predetermined portions thereof, said cap flap manipulating means operable during folding of said cap flaps to bring adjacent tray flaps together at said cap flap predetermined portions to secure said cap flaps together with said adhesive and maintain said post members at said predetermined locations with said post members disposed between tray flaps and said objects.

6. The apparatus according to Claim 4 additionally comprising spacer pad placement means for placing a plurality of spacer pads on said cap panel, said adhesive applicator means, prior to placement of said spacer pads on said cap panel, adapted to apply adhesive to said cap panel at predetermined areas of said cap panel to secure said spacer pads to said cap panel.

7. The apparatus according to Claim 1 wherein said bulk package defines a plurality of sides intersecting at corners, said preselected locations being at said corners and said post member positioning means comprising a plurality of post member positioning devices, each such post member positioning device adapted to position a post member at one of said corners.

8. The apparatus according to Claim 7 wherein each said post member positioning device includes magazine structure adapted to hold a plurality of post members, means for removing a post member from said magazine structure, and means for placing the removed post member into engagement with objects located at one of said corners.

9. The apparatus according to Claim 7 including means for varying the relative locations of said post member positioning devices.

10. The apparatus according to Claim 8 wherein said means for removing said removed post member includes a pick-up element movable between a first position whereat the pick-up element engages the post member at said magazine structure and a second position spaced from both said magazine structure and said objects.

11. The apparatus according to Claim 10 wherein said means for placing said removed post member into engagement with objects located at one of said corners includes a transport element for transporting said removed post member from said second position to objects at said one corner.

12. The apparatus according to Claim 10 wherein said pick-up element comprises a pivoted pick-up arm and a vacuum cup assembly on said pick-up arm, said vacuum cup assembly including at least one vacuum cup for engaging said post member at said magazine structure and applying a vacuum to said post member to retain said post member on said pick-up element during movement of said pick-up element between said first and second positions.

13. The apparatus according to Claim 12 wherein said vacuum cup assembly includes a vacuum cup support arm pivotally connected to said pick-up arm, said vacuum cup support arm supporting a plurality of said vacuum cups in spaced relationship.

14. The apparatus according the Claim 11 wherein said transport element includes a primary transport arm, an auxiliary transport arm movably mounted on said primary transport arm, first prime mover means for selectively moving said primary transport arm, and second prime mover means for selectively moving said auxiliary transport arm relative to said primary transport arm, said primary transport arm being movable by said first prime mover means in a generally vertical plane from a generally horizontal position to a generally vertical position, and said auxiliary transport arm being movable by said second prime mover means in a generally horizontal plane when said primary arm is in said generally vertical position.

15. The apparatus according to Claim 14 wherein said auxiliary transport arm includes a cradle element at the distal end thereof, said post members having a V-shaped cross-section and said cradle element including interconnected diverging sides generally corresponding to the configuration of said V-shaped cross-section.

16. The apparatus according to Claim 4 wherein said cap flap manipulating means comprises a first opposed pair of movable cap flap engaging plates and a second opposed pair of movable cap flap engaging plates, at least some of said cap flaps including a central cap flap portion and end cap flap portions hingedly connected to opposed ends of said central cap flap portion, said cap flap engaging plates of at least one of said pairs of movable cap flap engaging plates including a central cap plate segment for engaging and folding a central cap flap portion and end cap plate segments connected to the ends of and movable relative to said central cap plate segment to bend said end cap flap portions and place said end cap flap portions in face-to-face engagement with an adjacent cap flap.

17. The apparatus according to Claim 2 wherein said tray flap manipulating means comprises a first opposed pair of movable tray flap engaging plates and a second opposed pair of movable tray flap engaging plates, at least some of said tray flaps including a central tray flap portion and end tray flap portions hingedly connected to opposed ends of said central tray flap portion, said tray flap engaging plates of at least one of said pairs of movable tray flap engaging plates including a central tray plate segment for engaging and folding a central tray flap portion and end tray plate segments connected to the ends of and movable relative to said central tray plate segment to bend said end tray flap portions and place said end tray flap portions in face-to-face engagement with an adjacent tray flap.

18. The apparatus according to Claim 5 wherein said adhesive applicator means comprises a plurality of spray nozzles disposed in tiers for applying adhesive to said tray flap predetermined portions and said cap flap predetermined portions.

19. The apparatus according to Claim 8 wherein each said magazine structure includes a plurality of magazines, said magazines adapted to hold post members of differing predetermined lengths, said post member removing means adapted to selectively remove post members from any one of said magazines.

20. Apparatus for forming a bulk package having a plurality of sides intersecting at corners, said bulk package including objects stacked in layers with each layer comprising a plurality of objects disposed in rows, a bottom tray disposed under the lower-most layer, said bottom tray including a tray panel and tray flaps disposed at least partially about the periphery of said tray panel, a top cap disposed over the upper-most layer, said tray cap including a cap panel and cap flaps disposed at least partially about the periphery of said cap panel, and elongated post members located at said corners and extending between the bottom tray and top cap, each said post member being maintained at one of said corners by frictional engagement between said objects and said tray and cap flaps, said apparatus comprising, in combination:
bottom tray placement means for placing the bottom tray on a support;
stacking means for stacking said layers of objects on said bottom tray after placement of said bottom tray on said support;
top cap positioning means for positioning said top cap over the upper-most layer of objects after said stacking means has stacked said layers of objects;
post member positioning means for positioning said post members at said corners;

tray flap manipulating means for folding said tray flaps and bringing said tray flaps into engagement with said post members whereby the lower ends of said post members are maintained between the tray flaps and objects at said corners; and cap flap manipulating means for folding said cap flaps and bringing said cap flaps into engagement with said post members whereby the upper ends of said post members are maintained between the cap flaps and objects at said corners.