[0001] This application claims the benefit of U.S. Provisional Application No. 62/107,402 filed on January 24, 2015, U.S. Provisional Application No. 62/107,403 filed January 24, 2015, and U.S. Provisional Application No. 62/107,405 filed January 24, 2015, the contents of which are incorporated herein by reference in their entirety.

BACKGROUND

Field of the Invention

[0002] The invention relates generally to the field of food product processing, and more particularly to egg processing.

[0003] 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. Patent 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. Patent 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. 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.

[0008] 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.

[0009] 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 700ms. 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 [0013] 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.

[0014] 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

-5- [0023] 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.

[0024] 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.

[0025] 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. [0026] FIGs. 10A through 10D show different views of the active cleats in operation along a packer in accordance with the present disclosure.

[0027] FIGs. 11A through 1 1 B show additional different views of the active cleats in operation along a packer in accordance with the present disclosure.

[0028] FIGs. 12A through 12B show additional different views of the active cleats in operation along a packer in accordance with the present disclosure.

[0029] FIGs. 13A through 13B show additional different views of the active cleats in operation along a packer in accordance with the present disclosure.

[0030] FIGs. 14A through 14C show additional different views of the active cleats in operation along a packer in accordance with the present disclosure. [0031] FIGs. 15A through 15D show additional aspects of the carton lid closing system in accordance with the present disclosure.

[0032] FIGs. 16A through 16D show additional aspects of the carton lid closing system in accordance with the present disclosure.

[0033] FIGs. 17A through 17D show additional aspects of the carton lid closing system in accordance with the present disclosure.

-7- [0043] 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.

[0044] In FIG. 1 , an egg packing system 100 is shown having a plurality of packers 102, 104, 106 and 108 and a grader system 1 10 that passes the eggs to the packers which pack the eggs into packages 112, 1 14, 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

[0045] 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.

[0046] 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. 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.

[0049] 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.

[0050] 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 31 1.

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.

-11- 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.

[0054] 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.

[0055] 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 closable carton, or when there is no lid to close on the egg carton (e.g., egg flats). [0056] 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 conveyer chain 306 to the carton lid

-13- [0058] 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

[0059] 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. [0064] 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.

[0065] 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. [0066] 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.

[0067] 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

-17- 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.

[0069] 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.

[0070] 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. [0071] FIGs. 20 through 25 show the progressive action of the heel and disengagement ramp on successive cartons.

[0072] 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.

-19- 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. [0077] 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.

[0078] 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.

[0079] 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

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