APPARATUS AND METHOD FOR PACKAGING SIDING PANELS

FIELD OF THE INVENTION

[0001] The invention relates to production line machinery for sorting and packing articles, and in particular to such an apparatus for sorting and packing vinyl siding panels.

BACKGROUND OF THE INVENTION

[0002] Vinyl siding is commonly used in construction as the exterior cladding for homes and other structures and has the advantage of low maintenance and high resistance to weathering. Vinyl siding is easily applied by home remodelers and do-it-yourselfers. This siding is made by a known extrusion process with a common panel size of 8 inches wide by 12 feet long, although other lengths and widths can be used as appropriate. The siding is normally formed with a hanger strip along one edge which interlocks with a mating strip along the edge of an adjoining strip. These hanger strips complicate packing the strips in stacks within a box or carton, and to achieve maximum space efficiency, the strips are normally packed in alternate orientation. Moreover, stacking and packing of the panel strips is done by hand in most manufacturing plants. Accordingly, repetitive hand and wrist movement is required, which can lead to repetitive stress injury. In current practice, the panel strips are stacked in boxes or cartons which are then sealed and routed for shipment. The current work design, in some instances, also forces a reduction in extruder throughput because the packer cannot keep up.

[0003] Automated sorting and packing processes for siding have been developed, including the vinyl siding sorting and packing machine disclosed in U.S. Pat. No. 6,202,391 issued to K-Ter Imagineering, Inc. The patent discloses a siding panel sorting and packing machine having a siding receiving section, lifting and flipper arms for nesting the panels, a panel accumulation section, and a box folding section, However, the panels are placed into a pre-made carton by the operator. This lowers the overall production rate and allows ergonomic issues such as risk of injury to an operator, to persist.

[0004] There exists a need, therefore, for an apparatus and method for packaging siding panels that does not require the operator to place the siding panels into a pre-made carton. Such an apparatus and method would be instrumental in increasing the extrusion rate of the vinyl siding panels and reducing the ergonomic strain on the operator.

[0005] The object of the present invention, therefore, is to provide an apparatus and method for packaging siding panels that does not require the packer to place the siding panels into a carton and, therefore, substantially reduce the ergonomic strain on the packer while substantially increasing the vinyl siding panel packaging rate.

SUMMARY OF THE INVENTION

[0006] The present invention relates to an apparatus and method for packaging vinyl siding panels. The apparatus comprises a panel receiving section for positioning in line with a panel extrusion line, pins for inverting and stacking the panels atop each other with the pins being coupled to a frame supporting the panel receiving section and situated below the panel receiving section, a panel accumulation section situated below the panel receiving section and the pins, and a mechanism means, preferably a ram mechanism, situated at a first end of the panel accumulation section for pushing the panels from the panel accumulation section and into a container, such as a pre-made carton, situated at a second end of the panel accumulation section that is opposite the first end.

[0007] The method comprises moving the panels from the panel extrusion line to the panel receiving section and dropping the panels from the panel receiving section onto pins that invert and arrange received panels. When dropped, the panels are inverted as they hit the pins and drop into the panel accumulation section where they are stacked. The mechanism means, preferably a ram mechanism, pushes the stacked panels into the the pre-made carton and the carton is closed and ready for shipping. In this manner, the apparatus of the present invention facilitates an automated packing process which significantly reduces the level of operator participation in its operation.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 depicts an end view of an automated packaging apparatus in accordance with the present invention;

[0009] Figure 2A depicts a top view of an automated packaging apparatus in accordance with the present invention;

[0010] Figure 2B depicts a side view of an automated packaging apparatus in accordance with the present invention;

[0011] Figures 3A-3 J depict the operation of an automated packaging apparatus in accordance with the present invention; [0012] Figures 4A-4C further depict the operation of an automated packaging apparatus in accordance with the present invention; and

[0013] Figures 5A-5C depict the subsequent operation of an automated packaging apparatus in accordance with the present invention subsequent to the operation depicted in Figures 4A-4C.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0014] The present invention is designed to automatically package extruded vinyl siding or similar material such as vinyl soffit panels, in containers after manufacture. The apparatus of the present invention generally comprises a receiving section, a panel accumulation section and a transfer mechanism to transfer accumulated product into cartons. An end view of an apparatus in accordance with the present invention is shown in Figure 1. As depicted therein, in a preferred embodiment, a packer 100 comprises receiving arms 101 adapted to receive manufactured siding, soffit material or the like after the extrusion process is complete. Disposed beneath receiving anus 101 are inverting pins 102 which operate to orient and nest extruded siding or soffit elements after being received by receiving arms 101. Receiving arms 101 and inverting pins 102 are designed to swing through predetermined arcs in concert with one another to perform an orientation and nesting operation within packer 100. Nested siding panels are then positioned at the bottom of packer 100 where a predetermined number are allowed to accumulate. The precise quantity, positioning, transport and orientation of panels processed by packer 100 is controlled in part by electric motors 108, 109, 1 10, 104, 105, 114, and 115. In this

regard, motors 1 12 and 113 operate accumulation pins 103, thereby allowing the number of accumulated panels stacked below the accumulation pins 103 to be adjusted, while motors 114 and 115 operate to adjust jackscrews 106 and 116 respectively. Jackscrews 106 and 116 adjust the level of pins 102 upwardly or downwardly as desired by the packer 100 operator.

[0015] Packer 100 further comprises a motor 104 which operates a ram 118 for transferring stacked panels into cartons as explained below. Grabber motor 117 resides atop packer 100 and is connected to a roller which guides extruded siding toward receiving arms 101 for package processing. [0016] During operation of packer 100, accumulation pins 103 remain retracted until a predetermined number of panels is accumulated at the bottom of packer 100 (see figure 5J). When the desired number of panels to be packaged is accumulated, pins 103 are extended (see Figure 5A) thereby causing panels to accumulate on pins 103 and preventing further accumulation of panels at the bottom of packer 100. In this manner, pins 103 control the number of panels contained in a package.

[0017] Referring now to Figures 1 and 2A-2B, jackscrews 111 and 107 operate to adjust the level of receiving arms 101 and are driven by motors 201 and 202 respectively. Figure 2A depicts a top view of a packer 100 in accordance with the present invention and shows the layout of electric motors 113, 112, 201, 202, 108, 109, 110, 105, 201 and 202. Figure 2B depicts a side view of packer 100, more clearly depicting ram 118 and the orientation of grabber motor 117.

[0018] The operation of the packer 100 will now be described with reference to Figures 2, 3, 4A-4C and Figures 5A-5C. After siding or soffit panels have undergone the extrusion and manufacturing process, completed panels are guided towards grabber motor 117 and its associated conveyor, which transports individual extruded panels onto receiving arms 101. With reference to Figure 3 A, an extruded panel is shown positioned on receiving arms 101. At this point, receiving arms 101 are oriented such that the panel 301 remains level. Also shown in Figure 3 A is a short stack of 2 extruded siding panels that are resting on accumulating pins 103. Below the accumulating pins 103 resides a completed stack of siding panels that is ready for placement in a carton.

[0019] It should be noted that the conditions depicted in Figures 3A thru 3 J illustrate specific moments in time during the execution of a specific packaging profile in accordance with the present invention. Other packaging profiles are operator selectable and can be initiated to provide options in packaging specifics such as allowing an operator to vary the orientation and nesting of panels being processed by packer 100 and change the number of panels that are allowed to accumulate prior to packaging for example.

[0020] Accordingly, Figures 3A-3J illustrate the implementation of one of several possible packaging profiles. To process an extruded panel for packaging after placement on pins 101, and as depicted in Figures 3B and 3 C, the right side array of receiving arms 101 is swung away from the underside of panel 301 causing panel 301 to tilt and fall away from the left side receiving arm 101 which remains level. As shown in Figure 3D, the orientation of pins 102 causes the fallen panel 301 in Figure 3C, to come to rest at an angle and upside down with respect to its original position in Figure 3 A.

[0021] Referring now to Figure 3E, when the panel 301 of Figure 3D comes to rest, another panel 301 , is positioned on receiving arms 101 while the first panel 301 rests on pins 102, As is depicted in Figure 3F, this panel is allowed to fall near vertically by moving receiving arms 101 away from the panel such that when it comes into contact with the first panel 301 released in Figure 3A, the two panels form a nested pair as shown in Figure 3 G.

[0022] Referring now to Figure 3H, once a nested pair of panels is established as shown in Figure 3 G, the nested pair is released by moving inverting pins 102 away from the nested pair, thereby allowing the nested pair to fall on top of the accumulating panels resting on accumulating pins 103 as shown in Figure 31. As noted, earlier panels are accumulated on accumulating pins 103 only when the desired number of panels to be packaged has been reached at the bottom of packer 100 (as shown below accumulating pins 103 in Figures 3 A thru 31). Thus, initial accumulation of panels in packer 100 occurs below accumulation pins 103 as depicted in Figure 3 J wherein panels are shown accumulating at the bottom of packer 100 and below accumulation pins 103.

[0023] Referring again to Figure 31, when a stack of the desired size is achieved below pins 103 of Figure 31, a packaging sequence is initiated. A description of the packaging sequence follows with reference to Figures 4A-4C and Figures 5A-5C. As shown in Figure 4A, when a sufficient number of panels 402 has accumulated in a packer 100 in accordance with the present invention, a packaging sequence begins comprising a carton 401 mounted on a movable sled 403. In a preferred embodiment the movable sled 403 is pneumatically operated. The packaging operation begins when a carton 401 is moved towards the packer 100 on sled 403. As shown in Figures 4B and 4C when carton 401 is in close proximity to packer 100 and longitudinally and vertically aligned with panels 402, ram 118 is activated to drive the panels 402 into carton 401. In a preferred embodiment, cartons used in the present invention are erected and assembled by a carton erector 404 shown at the far end of sled 403 and as shown in Figures 4A-4C.

[0024] With reference now to Figures 5A-5C, once panels 402 are placed in carton 401, ram 118 is withdrawn to its original position as shown in Figure 5 A and the carton 401 is withdrawn from packer 100 as shown in Figure 5B. After withdrawal from packer 100 the loaded carton 401 is elevated as shown in Figure 5C and positioned for transfer from the packaging line.

[0025] Referring now to Figure 3J, depicted therein is the condition of packer 100 after accumulated panels have been transferred to a carton as described above with reference to Figures 4A-4C and 5A-5C. As depicted therein, once panels have been transferred from the bottom of the packer 100, accumulation pins 103 are retracted and panels 301 are allowed to accumulate below accumulation pins 103. When the desired quantity of panels 301 are accumulated, the condition depicted in Figure 3 A, wherein accumulation pins 103 are extended and panels 301 are allowed to accumulate on accumulation pins 103 until the accumulated panels located below accumulation pins 103 are cleared by the cycle described above in relation to Figures 4A-4C and 5A-5C.

[0026] While specific embodiments of the invention has been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure and maybe otherwise embodied within the scope of the appended claims.