SYSTEM FOR PRESS FITTING AN EATING IMPLEMENT

INTO A STORAGE POSITION ON A CONTAINER

Technical Field of the Invention

The present invention relates to a system, method and apparatus for press fitting an eating implement into a storage position on a lid of a container. Background of the Invention

Australian Patent No 754978. (AU 754978) generally discloses a lid for a container that includes an implement coupled thereto by a hinge. As shown in Figures 1 to 4, the implement 3 is, for example, a spoon that is shaped for extracting food from the container 1. The hinge 4 allows the implement 3 to be rotated about an axis between :

1. a storage position in which the implement 3 lies against a cover portion 5 of the lid 2; and

2. an in use position in which the implement 3 extends outwardly of the lid 2 to enable the implement 3 to be used to remove contents from the container 1.

The hinge 4 preferably includes at least one frangible tab 6 such that severing of the frangible tab 6 detaches the implement 3 from the cover portion 5. Further, the cover portion 5 of the lid 2 includes retaining means 7 for retaining the implement in the storage position. The disclosure of the patent specification of AU 754978 is hereby incorporated herein by way of reference.

The lid being the subject of AU 754978 is a formed single piece plastic container lid with a utensil attached. During production, the following steps are performed :

1. injection mould machine forms the lid with the implement attached ;

2. lids are retrieved from the injection mould machine;

3. implements are folded and press fitted to respective lids; and

4. the lids are stacked. The steps of folding and press fitting are manual processes performed by production line workers. Use of production line workers to perform these steps may slow down production time and make manufacturing such lids inefficient and costly. It is generally desirable to overcome or ameliorate one or more of the above mentioned difficulties, or at least provide a useful alternative.

Summary of the Invention According to the present invention, there is provided a system for press fitting an eating implement into a storage position of a lid on a container, said system for performing the steps of:

(a) retrieving a lid from an injection mould machine;

(b) transferring the lid into a nest; and

(c) press fitting an implement into a storage position on the lid .

Preferably, the implement is shaped for extracting food from the container. Preferably, the lid includes retaining means for securing the implement in said storage position.

Preferably, the step of transferring the lid into the nest includes the step of a lid suction device engaging an underside of the lid and positioning the lid in the nest. Preferably, the step of press fitting the implement to the into the storage position includes the steps of:

(a) a second suction device engaging a head end of the implement;

(b) the lid suction device disengaging the underside of the lid ;

(c) moving the head of the implement relative to the nest such that the head end of the implement moves towards the storage position; and

(d) the second suction device disengaging the head of the implement.

Advantageously, the step of moving the head end of the implement relative to the nest is effected by lateral movement of the nest towards the second suction device, and vertical movement of the second suction device into the nest.

Brief Description of the Drawings Preferred embodiments of the present invention are hereafter described, by way of non-limiting example only, with reference to the accompanying drawing in which :

Figure 1 is a perspective view of a prior art container fitted with a lid;

Figure 2 is a partial vertical section of the container and the lid shown in Figure 1 ; Figure 3 is an enlarged cross-sectional view of the area at "A" in Figure 2;

Figure 4 is an underneath perspective view of the lid shown in Figure 1;

Figure 5 is a top perspective view of a lid for a container;

Figure 6 is a bottom view of the lid shown in Figure 5;

Figure 7 is a bottom view of the lid shown in Figure 6 arranged in another condition of use;

Figure 8 is a side view of the lid shown in Figure 5 arranged in another condition of use;

Figure 9 is a side view of an apparatus for folding and press fitting an implement onto the lid shown in Figure 5;

Figure 10 is a section view through the line A-A of the apparatus shown in Figure 9; and

Figure 11 is a front view of the apparatus shown in Figure 9.

Figure 12a is a plan view of the apparatus shown in Figure 9 operating with an injection mould machine in a closed condition of use;

Figure 12b is a side view of the apparatus shown in Figure 12a;

Figure 12c is a left side perspective view of the apparatus shown in Figure 12a;

Figure 13a

Detailed Description of Preferred Embodiments of the Invention

The Lid 100

The overcap 100 shown in Figures 5 to 8 (also referred to as the lid 100) is adapted to be used with a yoghurt container (not shown), for example. The lid 100 includes a generally planar cover section 102 that extends over an opening of the contain and skirt 104 that extends downwardly around an outer periphery of the cover section 102. The skirt 104 includes a mating section 106 that is shaped to couple with an upper peripheral section of the container. The lid 100 is thereby secured to the container. Of course, the shape of the lid 100 (including the skirt 104 and the mating section 106) will vary to complement the shape of any container of interest.

The lid 100 includes an implement 108 coupled to a section 110 of the lid 100 by an implement hinge 112. As shown in Figures 5 to 9, the implement 108 includes a head 109 that is shaped for extracting food from the container. For example, the head 109 forms a spoon, a fork, a spork, or any other suitable implement. The implement hinge 112 allows the implement 108 to be rotated about an axis between:

1. the storage position shown in Figures 5 and 6, where the implement 108 lies against the cover section 102 of the lid 100; and

2. the in use position shown in Figures 7 to 9, where the implement 108 extends outwardly from the lid 100 to enable the implement 108 to be used to remove contents from the container.

The implement hinge 112 includes at least one frangible section 114 such that severing of the frangible section 114 detaches the implement 108 from the cover section 102. Operation of frangible sections with a lid is described in AU 754978.

As particularly shown in Figures 7 to 9, the implement 108 includes first and second elongate arms 108a, 108b coupled together by an arm hinge 116. The elongate arms 108a, 108b rotate 180 degrees about the arm hinge 116: a. from a collapsed position where the elongate arms 108a, 108b are arranged side by side; and

b. to an expanded position where the elongate arms 108a, 108b are collinear, as shown in Figure 7.

In the second elongate arm 108b extends from an end of the first elongate arm 108a.

Rotation of the second elongate arm 108b with respect to the first elongate arm 108a about the arm hinge 116 is limited by abutment of respective end sections 118. To inhibit further rotation, the first elongate arm 108a includes an elongate rib 120 extending from said end section 118 of the first elongate arm 108a into a corresponding slot 122 of said end section 118 of the second elongate arm 108b. As shown, the rib 120 has a "V" shaped cross-section having an apex 124 facing the arm hinge 116. In use, as the second elongate arm 108b is rotated towards the expanded position, the rib 120 enters into the slot 122. Further rotation is inhibited by the rib 120 abutting a surface of the slot 122. In an alternative embodiment, the rib 120 has any other suitable shape for mating with a corresponding slot of the second elongate section 108b.

Further, the lid 100 includes retaining means 126 for retaining the implement 108 in the storage position. As particularly shown in Figure 8, the retaining means 126 is in the form of a protrusion extending outwardly from the cover section 102. The protrusion 126 is shaped to mate with and extend at least partially through one or more corresponding openings 128 of the spoon 108. Frictional engagement between the protrusion 126 and the openings 128 secures the spoon 108 in the storage position. Alternatively, the retaining means 126 can be any other suitable means for coupling the implement to the lid by way of press fitting.

As particularly shown in Figure 9, the implement hinge 112 is formed in four sections 130a, 130b, 130c, 130d hingedly coupled together in series. Specifically, the sections are coupled together as follows:

1. the first section 130a is coupled between the skirt 104 and the frangible section 114;

2. the second section 130b is hingedly coupled between the frangible section 114 and the third section 130c;

3. the third section 130c is hingedly coupled between the second section

and the fourth section 130d ; and

4. the fourth section 130d is hingedly coupled between the third section 130c and the first elongate arm 108a of the implement 108. When the implement is being arranged in the storage position, the second, third and fourth sections 130b, 130c, 130d are arranged to come up over and down the mating section 106 of the lid 100. The implement hinge 112 can thereby be attached to an outer side of the lid whilst being located inside the lid in the storage position. The lid 100 is a formed single piece plastic container l id with a utensil 108 attached .

System 200 for Press Fitting the Implement to the Lid

The system 200 shown in Figures 10 to 14c includes:

1. folding spoon frame apparatus 300;

2. z-axis apparatus 400;

3. main axis apparatus 500 coupled to a take out head 600; and

4. a control system 800.

The operation of each of these sections is described in further detail below. 1. Folding spoon frame apparatus 300 The folding spoon frame apparatus 300 includes:

1. four elongate members 302a, 302b, 302c, 302d coupled together to form a generally rectangular subframe 302;

2. rectangular spacers 304 overlying respective elongate members 302b, 302d of the su bframe 302;

3. a bearing block 306 coupled to and overlying the spacers 304;

4. parallel rails 308 coupled to respective sides of the bearing block 306;

5. first and second tooling sliding tables 310a, 310b, each bridging the rails 308 so as to be movable back and forth in direction D _TST ;

6. first and second drive means 312a, 312b for moving respective fi rst and second tooling slide tables 310a, 301b along rails 308;

7. four lid nests 314 securely coupled to respective sections of the tooling slide tables 310a, 310b; The nests 314 each include vacuum ducts 316 which are in fluid communication with a pneumatic controller 318.

As particularly shown in Figure 18b, the lids 100 can be secured to respective nests 314 when the pneumatic controller effects suction through the conduits 316. Similarly, the lids 100 can be removed from respective nests 314 when the pneumatic controller breaks suction to nests through the conduits 316.

2. Z-Axis Apparatus 400 The z-axis apparatus 400 includes:

1. an elongate shaft 402 coupled to translation apparatus 404 which includes a servo motor and gear box. These components are mechanically coupled to a tooth belt which is attached to the z axis. By rotating the motor one direction you move the z- axis up and in the other direction it moves down. The z-axiz belt drive effects up and down movement of the shaft 402 in direction D _z ; and

2. a stacker head 406 hingedly coupled to an end 408 of the shaft 402.

The stacker head 406 includes:

a. an "L" shaped bracket 412 coupling the end 408 of the 402 to a rotator

414, the rotor 414 for rotating the head 406 about axis "A _S H" between the hand over position shown in Figure 15b and the folding position shown in Figure 19;

b. a bracket 416 coupling the rotor 414 to a generally planar block 418; c. four pneumatic cylinders 420 coupled to and extending downwardly from the block 418;

d. four lid suction devices 422, each coupled to an end of a respective pneumatic cylinder 420; and

e. four spoon suction devices 424, each being coupled to a bracket 426 extending downwardly from the block 418.

The pneumatic cylinders 420, the lid suction devices 422, and the spoon suction devices 424 are arranged in groups around the block 418 such that each group can interact with a lid 100 seated in a corresponding nest 314 on the folding spoon frame apparatus 300. The pneumatic cylinders 420 are operable to move corresponding lid suction devices 422 towards and away from respective nests 314 in direction D _z . The z-axis is mounted to the main machine frame via the bracket just below 400.

3. Main Axis Apparatus 500 coupled to a take out head 600

With reference to Figures 14a to 24, the main axis apparatus 500 includes: a. an elongate horizontal track 502 including a base section 504 supporting two spaced apart parallel tracks 506a, 506b;

b. sliding carriage 508 mounted on the tracks 506a, 506b, the carriage 508 being movable along the track 502 in direction D _S i_; and

c. a bracket 510 coupled between the carriage 508 and the take out head 600.

The main axis apparatus 500 is operable to move the carriage 508 between the retracted position shown in Figures 14a to 14c and the pick up position shown in Figures 15a to 15b where the head 600 is located between parts of an injection mould machine 700 so as to retrieve newly made lids 100 therefrom.

The take out head 600 includes an outrigger 602 coupled to the bracket by an arm 604.

4. Control System 800 As particularly shown in Figure 24, operation of the folding spoon frame apparatus 300, the z-axis apparatus 400 and the main axis apparatus 500 is controlled by the control system 800 which includes: a. a programmable logic controller (PLC) 802 that continuously monitors the state of input devices and makes decisions based upon a custom program to control the state of output devices;

b. a human machine interface (H I) 804 in communication with the PLC 802; c. a safety control unit 806 in communication with the PLC 802;

d. the injection mould machine 700 in communication with the PLC 802;

e. a variable speed drive (VSD) 808 in communication with the PLC 802 via the safety control unit 806;

f. the following pairs of motors and controllers:

i. main axis motor and controller 810a, 810b;

ii. stacker motor and controller 812a, 812b;

iii. first outrigger motor and controller 814a, 814b; and

iv. second outrigger motor and controller 816a, 816b;

g. a conveyor 818 in communication with the PLC 802 via the VSD 808;

h. a first actuator 820a and controller 820b;

i. a second actuator 822a and controller 822b;

j. a pneumatic controller 824 in communication with the PLC 802 via the main axis controller 810b; and

k. a plurality of pneumatic i/o devices 826 in communication with the pneumatic controller 824. Further, circuit diagrams for the drivers are shown in Figures 25 to 28 and circuit diagrams for the servos are shown in Figures 29 and 30. Figure 31 is a schematic overview of the network signals for the servo positioning drives.

Operation of the System 200

In use, the injection mould machine 700 forms the lid 100 with the implement attached. The processes performed by the injection mould machine 700 to form the lid 100 are known in the art and are not described here in further detail.

With reference to Figures 10 to 31, the system 200 performs the following steps to retrieve the lid 100 from the injection mould machine 700 and to press fit the implement 108 to the cover section 102 of the lid 100:

1. the main axis apparatus 500 starts in the waiting position shown in Figure 14a to 14c with the take out head ready to retrieve the lids 100 from the injection mould machine 700;

2. the injection mould machine 700 sends a signal to the PLC 802 to indicate that the mould is open;

3. on receipt of a mould open signal from the injection mould apparatus 700, the the system 200 signals to the injection mould machine 700 that it is in place to receive;

4. Main axis move command captures HMI target position;

5. PLC executes main axis move command and the main axis apparatus 500 drives the carriage 508 down the tracks 506a, 506b in direction D _E so as to locate the take out head 600 between the parts 702a, 702b of the injection mould machine 700;

6. Static generation turned on. Static generation is the device which produces a high voltage charge for the IML labels that are put into the molds. The allows the label to stick to the face of the mould by way of static attraction;

7. Lids 100 seated in moulds 704 of the injection mould machine 700;

8. Mould area clear signal is turned off as head 600 breaks the light beam;

9. Outrigger axis monitors main axis 500 position;

10. Upon reaching intermediate position (set in PLC code), outrigger move command is executed to send the outrigger 602 to waiting position (close to mould face - set in HMI);

11. Main axis 500 reaches target position, PLC 802 is notified ;

12. Take out vacuum system on Outrigger 2 turned on;

13. Outrigger move commands issued to send outrigger 602 to respective mould positions (set in HMI 804);

14. Outrigger axis reaches the position, PLC 802 notified ;

15. IMM 700 turns off vacuum to each of the transfer heads;

16. Label is charged with static;

17. Label jumps to mould face of outrigger 602;

18. Take out head 600 acquires vacuum confirmation of all four parts 100 picked up;

19. PLC 802 sends signal to IMM 700 to eject;

20. IMM 700 outputs signal to PLC 802 that eject is starting;

21. Outrigger 602 executes move to match eject speed;

22. the lids 100 are extracted and coupled to respective sections 606 of the take out head 600;

23. the main axis apparatus 500 removes the take out head 600 from the injection mould machine 700 by moving the carriage 508 in direction D _R towards the transfer position in the manner shown in Figures 16a and 16b;

24. Outriggers 602 move back towards home position shown in Figures 16a and 16b; 20. Main axis monitors outriggers 602 and executes a move back to home position when outriggers are clear of mould faces;

21. Mould area clear signal is reinstated as head clears light beam;

22. PLC 802 sends signal mould clear signal to IMM 700 to proceed with next mould sequence;

23. the main axis apparatus 500 positions the take out head 600 in the transfer position shown in Figure 17a to 17c, where the lids 100 attached to the take out head 600 are arranged adjacent lid suction devices 422 of the stacker head 406, and the PLC 802 is notified;

24. Stacker head vacuum turns on;

25. Take out outrigger 602 moves to transfer position (set on HMI 804);

26. Folding spoon nests 314 move to load position;

27. As the product 100 is handed over, the stacker head 406 acquires vacuum signal;

28. Take out heads 600 vacuum turns off;

29. Take out outrigger 600 moves to home (and if labels have been picked main axis moves to waiting position waiting for step 1 above);

30. the stacker head 406 rotates 90 degrees (rotating downwards looking for a reed switch) to down position so that the block 418 is substantially horizontal so that the lids 100 are positioned over respective nests 314 of the folding spoon frame apparatus 300, in the manner shown in Figure 10 to 13;

31. PLC 802 confirms that the stacker head 406 has reached the rotated position;

32. Z axis 400 moves down in direction D _z to place lid position (set in HMI 804);

33. Folding Spoon Nest 314 acquires vacuum, signal on;

34. vacuum ducts 316 of the nests 314 secure the lids 100 in position in the manner shown in Figures 18a and 18b;

35. spoon suction devices 424 of the stacker head 406 engage respective spoons 109 in the manner shown in Figures 19 and 20;

36. lid suction devices 422 disengage respective lids 100 and retract;

37. Z Axis 400 moves up in direction D _z to intermediate position (set in HMI 804); 38. to effect a folding action, the following steps are performed simultaneously: a. first and second tooling sliding tables 310a, 310b separate in the manner shown in Figure 21 such that the first and second arms 108a, 108b of the implement 108 bend about hinges 116, 130a, 130b, 130c, 130d and are folded into the lid 100 so as to overlie the cover section 102;

b. the elongate shaft 402 of the z-axis 400 is lowered so that the folded arms 108a, 108b of the implement 108 are pressed into the lid 100 and bear against the cover section 102; and

c. the protrusion 126 is fitted through the slots 120 of the arms 108a,

108b as the z-axis is lowered and the first and second tooling sliding tables 310a, 310b separate so that the implement 108 is press fitted into the secured position shown in Figures 5 and 6;

39. Lid lift cups turn on, vacuum confirmation acquired;

40. the nest suction devices 316 are turned off which gives a small blow off (a positive air pressure to eject the assembled lids from the nests);

41. the elongate arm 402 of the z-axis 400 lifts the folded lids 100 out of respective nests 314 to a clear position;

42. the first and second tooling sliding tables 310a, 310b further separate in the manner shown in Figure 22 to the out position, drives signal when reached;

43. the elongate arm 402 of the z-axis 400 lowers the folded lids 100 down through the separated tooling sliding tables 310a, 310b onto a conveyer in the manner shown in Figure 23 and stacked;

44. Lid lift and spoon vacuum turned off where the product 100 gets released; 45. the number of lids 100 stacked is counted, and if a target number has been reached, the conveyor indexes the set along so that there is room for the next set; and

46. the system 200 returns to the waiting position shown in Figure 14a to 14c with the take out head ready to retrieve the lids 100 from the injection mould machine 700.

The system 200 is effected by the computer system 800 shown in Figure 24 which controls operation of its various component parts. The computer system 800 controls all the moving parts in a coordinated fashion to achieve the correct positioning before the parts are pressed together. This also then coordinates the axis to stack the product on a conveyor.

The tolerance between the slots 128 and pin 126 on the plastic product 100 is important. Also the plastic of the implement 108 is strong enough to allow press fitting. Many modifications will be apparent to those skilled in the art without departing from the scope of the present invention The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that the prior art forms part of the common general knowledge in Australia

In this specification and the claims that follow, unless stated otherwise, the word "comprise" and its variations, such as "comprises" and "comprising", imply the inclusion of a stated integer, step, or group of integers or steps, but not the exclusion of any other integer or step or group of integers or steps.

References in this specification to any prior publication, information derived from any said prior publication, or any known matter are not and should not be taken as an acknowledgement, admission or suggestion that said prior publication, or any information derived from this prior publication or known matter forms part of the common general knowledge in the field of endeavour to which the specification relates.

List of Parts

100 Overcap, Lid

102 Cover section

104 Skirt

106 Mating section

108 Implement

108a First elongate arm

108b Second elongate arm

109 Head

110 Section of lid

112 Implement hinge

114 Frangible section

116 Arm hinge

118 End section

120 Rib

122 Slot

124 Apex

126 Retaining means

128 Opening of spoon

200 System

300 Folding spoon frame apparatus 302 Subframe

302a, 302b Elongate member of subframe

302c, 302d Elongate member of subframe

304 Rectangular spacer

306 Bearing block

308 Rail

310a, 301b Tooling slide table

312a, 312b Drive means

314 Nest

316 Suction conduit

318 Pneumatic controller 814a, 814b First outrigger motor and controller

816a, 816b Second outrigger motor and controller

818 Conveyer

820a, 820b First actuator and controller

822a, 822b Second actuator and controller

824 Pneumatic controller

826 Pneumatic i/o device