Related Art [0002] Many foods, drinks, household products, and other fluids are currently packaged in plastic containers. During container manufacture, as well as subsequent processing, such as storage and retrieval of empty containers, and filling and packaging of containers, efficient systems for conveying containers are required. Retrieval systems interact with conveyance systems to gather, stack and store empty containers for use during operational interruptions and to make up for peak demand or for transferring filled or empty containers to different process stages.

[0003] One type of existing system for accomplishing these objectives utilizes table top conveyors, on which containers stand, and lane changing devices such as gates and diverters. When utilizing such systems, transition points (e. g., gates, diverters and feed points) are chronic sources of jams, damage and downtime. Additionally, many container designs do not run efficiently on table top conveyors due to instability of top heavy, empty containers or the inability of the containers to remain upright at top line speeds. Transferring containers from an air conveyor to table top conveyor requires additional floor space and control equipment, further increasing system complexity.

[0004] An alternative to a table top conveying system is a pneumatic conveyer. Existing air conveyor designs typically use a plenum and rail arrangement as exemplified in, for example, U. S. Patent No. 6,293, 736. In this arrangement a plenum is constructed to contain and direct pressurized air. The plenum is located above the rails on which the container is moved. A neck support section and air channeling louvers are mounted to the bottom of the plenum. The neck support section holds the container by the neck flange and the

louvers channel pressurized air onto the neck or finish of the container to provide the motive force. Containers move along the length of the neck support rails as a reaction to the motive force of the pressurized air.

[0005] Such plenum designs may incorporate features such as dump gates and articulating neck guides. A dump gate is an articulating section of neck support rails used to clear line jams. Typically, a system will be built that can sense an interruption in container travel, caused by, for example, a stuck or damaged container, and clear itself by articulating the neck support rails open far enough to allow a section of containers to"dump"out, thus clearing the jam.

Typical articulation distances are 12 mm to 15 mm.

[0006] Quick change neck guides use an arrangement in which the neck guides can be opened or closed to change center distance in a precision manner. This can be accomplished in either an automated manner by, for example, an actuator attached to the neck guides, or by manual adjustment of the neck guides. A change in spacing of the neck guides allows containers having different neck sizes to be run on the same piece of equipment. Typical articulation distances are no more than 10 mm to 15 mm.

[0007] One drawback to existing pneumatic conveyance systems is the inaccessibility to containers. Because of the presence of the plenum above the conveyance system, containers are only accessible from below. As a result, access at the retrieval and removal points is limited, and separate systems for retrieval and removal are required.

[0008] There thus remains a need for systems that can efficiently convey containers during manufacture and processing that is not subject to jams and the resultant downtime, and allows for simplification of retrieval, removal and loading systems. There is also a continuing need for systems with increased simplicity that do not rely on moving containers to a secondary handling system for removal and replacement. There is a further need for flexible systems where the removal and/or replacement of containers can be initiated from the top or the bottom of the system. Systems that can fit in the same footprint as existing systems are also beneficial.

[0009] These and other objectives and advantages are achieved by the present invention.

BRIEF SUMMARY OF THE INVENTION [00010] A pneumatic conveyor system that includes a pair of neck guides, one or both of which is moveable, for example by a connected actuator, relative to a container being conveyed. The neck guides include a neck support rail for holding a suspended container as it is being conveyed; and a plenum with a means for diverting the flow of pressurized air out of the plenum, for example a louver, to provide a motive force for conveying the container along the neck support rail. Typically, the neck guide or guides move in a direction perpendicular to a pair of neck support rails and a central axis of the container, for example to provide an opening of from about 10 mm to about 75 mm between the neck support rails to allow removal of the container. The neck guide is sufficiently moveable to allow vertical or horizontal removal of the container from- the conveyance system.

[00011] The system can also include a base plate that is extendable to support the container when the neck guide is moved. A base plate actuator attached to the base plate can be used for moving the base plate in a direction perpendicular to the neck support rail and parallel to a central axis of the container. The base plate can include a conveyor, such as a conveyor belt, for moving the container after it is released from the neck guides.

[00012] The system can further include a body plenum positioned below the neck support rail that include body plenum diversion means for diverting the flow of pressurized air out of the body plenum to convey the container. The body plenum can be connected to one or more actuators for horizontal or vertical movement of the body plenum.

[00013] A method for conveying containers along the conveyance system is also provided. After the container is released by moving the neck guides, it can be transferred to a second conveyor system. Examples of transferring the containers include placing the container on a table top conveyor; moving the container with a robotic arm or gripper; and moving the container with a vacuum cup. The table top conveyor can be part of the base plate.

[00014] The apparatus also provides methods for removing a container from a conveyance system facilitated by the absence of a plenum above the conveyance system. For example, the container can be removed by moving the

neck guides by an amount sufficient to remove the bottle through an opening between the neck guides. Removal can also include raising the base support plate to come in contact with the container in order to support the container when the neck guides are moved. The base support plate can be raised further by an amount sufficient to raise the neck of the container above said neck guides to facilitate removal of the container. Alternatively, side guides can take the place of the body plenum, and these can be moved to contact and support the container when the neck guides are moved. As yet another alternative, a vacuum plate can be contacted with a surface of the container to support the container when the neck guides are moved.

[00015] Further objectives and advantages, as well as the structure and function of preferred embodiments will become apparent from a consideration of the description, drawings, and examples.

BRIEF DESCRIPTION OF THE DRAWINGS [00016] The foregoing and other features and advantages of the invention will be apparent from the following, more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.

[00017] FIG. 1 depicts a perspective view of a container conveying system according to the invention ; [00018] FIG. 2 is a cut away view of one side of the conveying system depicting the constituent components; [00019] FIG. 3 is a cross sectional view through a section of an embodiment of the conveying system according to the invention in a normal operating configuration; [00020] FIG. 4 is a cross sectional view through a section of an embodiment of the conveying system according to the invention in a configuration of a stage of container removal; [00021] FIG. 5 is a cross sectional view through a section of an embodiment of the conveying system according to the invention in a configuration of another stage of container removal; and

[00022] FIG. 6 is a cross sectional view through a section of an embodiment of the conveying system according to the invention in a configuration for container removal.

DETAILED DESCRIPTION OF THE INVENTION [00023] Embodiments of the invention are discussed in detail below. In describing embodiments, specific terminology is employed for the sake of clarity.

However, the invention is not intended to be limited to the specific terminology so selected. While specific exemplary embodiments are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations can be used without parting from the spirit and scope of the invention. All references cited herein are incorporated by reference as if each had been individually incorporated.

[00024] The shortcomings in the prior art can be avoided by a container conveyance system that does not necessitate diverting containers out of the normal operation area for retrieval and replacement. The retrieval and removal point of the present invention is configured to be an integral part of the conveyance system. This is accomplished by a novel configuration of supports, plenums and articulating neck guides. Vertical (top or bottom) entry and exit points in a section of the conveyance system allows for access of automated equipment to retrieve and replace containers without the need to send containers to a side stream system.

[00025] As shown in Fig. 1, the conveyance system 100 includes a neck guide 102 for holding a container 104 by the neck flange 106. Each of the neck guides 102 includes a neck support rail 108 which holds the container 104 by the container neck flange 106. Each neck guide 102 further includes a plenum 110 through which pressurized air is conveyed. The plenum 110 includes diversion means 112 which may be, for example, a louver, for directing the flow of pressurized air out of the plenum 110 and onto a neck 114 of the container 104.

Thus, as pressurized air flows through the plenum 110 it exits out of the diversion means 112 and is directed onto the neck 114 to convey the container 104 along the neck support rails 108. At least one of the neck guides 102 is movable relative to the container by an actuator 116. Activation of the actuator 116 causes the neck guide 102 to move, expanding the opening between the pair of neck guides 102 to allow vertical movement of the bottle in the conveyance system 100. For standard

size containers, the articulation distance may be from about 10 mm to about 75 mm. For other applications, different articulation distances can be used depending on the specific application. Distances can be varied by, for example, appropriate modification of the neck guide and actuators.

[00026] In an exemplary embodiment, the conveyance system includes a base plate 118 that is movable in a vertical direction for lifting the container 104.

The base plate 118 can include a secondary conveyance system such as, for example, a belt or vacuum cups, for conveying the containers after they are released from the neck guides, as described further below.

[00027] The conveyance system 100 can also include a body plenum 120 which can be attached through a body plenum support 122. The body plenum 120 also serves to carry pressurized air, which can be diverted out of the body plenum 120 onto the body of container 104 to further assist in conveyance of the container 104 along the neck support rail 108. The body plenums, if present, can also articulate to move away from the containers to allow for side entry of a robotic arm of other removal device.

[00028] Fig. 2 is a cut away view showing one-half of the system for conveying containers in order to show the component features of an embodiment of the conveyance system 100. As shown in Fig. 2, the neck support rail 108 can be comprised of a rail 202 and a rail support 204. The plenum 110 is situated above the neck support rail 108. The diversion means 112 which, in the embodiment of Fig. 2, comprise louvers along the plenum 110, allow the exit of pressurized air in a direction indicated generally by the arrow shown as 206.

Similarly, the body plenum 120 includes body plenum diversion means 208 which, in the embodiment of Fig. 2, comprise louvers. Pressurized air directed through the body plenum 120 exits through the body plenum diversion means 208 also forcing air in the direction indicated by the arrow 206. Actuator 116 for moving the neck guide 102 is attached to the neck guide 102 at a point opposite the position of the neck support rail 108 and the diversion means 112. The actuators 116 can be activated in order to move the neck guide 102 in a lateral direction away from the container, which would be suspended from the rail 202.

The actuator 116 can be connected to the neck guide 102 through the plenum 110 or rail support 204. The body plenum 120 is similarly connected to body plenum

support 122. The body plenum support 122 can be an actuator for moving the body plenum 120. In such an embodiment, the body plenum 120 can be moved by activating the actuators that make up the body plenum support 122 in order to accommodate containers having different body sizes and shapes. The body plenum support 122 can also comprise an actuator or additional actuator for moving the body plenum 120 in a vertical direction to allow access to the containers 104 from the side.

[00029] Fig. 2 further illustrates the base plate 118 and its attachment to base plate actuators 210. Activation of the base plate actuators 210 causes movement of the base plate in a vertical direction as indicated by arrow 212.

Thus, when desired, the base plate 118 can be raised relative to the container for purposes of lifting the container as described further below.

[00030] Fig. 3 is a cross section through the conveyance system 100 in its normal operating configuration, i. e., when the various components are positioned for conveyance of a container 104 along the neck guide 102. The embodiment of Fig. 3 shows two conveyance systems 100 operating in parallel in a side-by-side fashion. It will be understood by persons of ordinary skill in the art <BR> <BR> that the conveyance system 100 may comprise a single conveyance system, i. e. , a single pair of neck rails and plenums, two parallel conveyance systems as shown in Fig. 3, or more than two conveyance systems. When in the normal operating configuration, the base plate 118 is positioned below the container 104 so that the container is free to move along the neck support rail 108 without contacting the base plate 118. Further, because of the position of the base plate 118, the container 104 is suspended from the neck support rail 108 by the neck flange 106.

The container neck 114 extends in an upward direction beyond the neck flange 106 and into the space between the plenum 110 located on each neck guide 102.

Thus, the container 104 is suspended on the neck support rail 108 by the neck flange 106 as it is conveyed through the conveyance system 100. It can be further seen that the neck support rails 108 are positioned to allow clearance of the portion of the container 104 below the neck flange 106 and at a width that minimizes contact with the neck flange 106 to reduce resistance to conveyance.

The actuators 116 connected to the neck guides 102 are movable such that a variety of container neck sizes can be accommodated by the conveyance system

100. In operation, pressurized air in the plenum 110 exits through the diversion means 112 and onto the neck 114 of the container, tending the container 104 along the neck support rail 108. In the embodiment of Fig. 3, actuator 116 is attached to the neck guide 102 at the rail support 204. As stated above, the actuator 116 may be attached at any point along the neck guide 102 so long as it allows for movement of the neck guide 102 towards and away from the container 104 being conveyed.

[00031] Fig. 3 further shows the base plate actuator 210 located beneath the base plate 118. The base plate actuator 210 can be extended to raise the base plate 118 in a direction towards the container. The embodiment of Fig. 3 further includes the body plenum 120 and the body plenum diversion means 208. The body plenum 120 is supported by body plenum support members 122 which may also be actuators allowing for movement of the body plenum 120 in a lateral direction toward and away from the containers. These actuators or additional actuators associated with the body plenum 120 can be included to move the body plenum 120 in a vertical direction. As is apparent from Fig. 3, the conveyance system 100 of the present invention omits the use of a large plenum above the containers in order to allow for vertical removal of the containers from the conveyance system, as described further below.

[00032] Fig. 4 shows a configuration of the conveyance system 100 during a stage of activation for container removal. As shown in Fig. 4, the base plate actuators 210 can be activated to raise the base plate 118 to come in contact with the container 104. Further, the base plate actuators 210 have been activated to a degree necessary to lift the containers 104 by an amount such that the neck flange 106 of the container is no longer in contact with the neck support rail 108.

Thus, during this stage, the container is no longer suspended from the neck support rail 108, but is supported by the base plate 118.

[00033] In another step in the process of configuring the system for container removal, shown in Fig. 5, the neck guide actuators 116 are activated to move the neck guides 102 into an open configuration away from the containers 104. At the stage shown in Fig. 5, the distance between the neck support rails 108 is greater than the width of the body of the container 104. Thus, the neck support rails 108 are sufficiently spread apart to allow for vertical removal of the container

104, i. e. , removal of the container 104 in a direction that would take it between the neck support rail 108. In this embodiment, it is not necessary for the body plenum 120 to move away from the body of the container 104 as the container has substantially the same diameter along its body. If the container body were flared out such that a portion of the body below the body plenum 120 was wider than the space between the body plenums 120, the body plenum supports could be in the form of actuators for moving the body plenum 120, and widening the gap therebetween to allow for removal of the container 104.

[00034] In another stage of the container removal process, shown in Fig. 6, the base plate actuators 210 are further extended in order to raise the base plate 118 by an amount sufficient to lift the container 104 such that the neck 114 is positioned above the neck guide 102, more particularly above plenum 110. As is further evident from Fig. 6, the neck guides 102 are sufficiently spaced to allow removal of the container 104 from between the neck guides 102 without the neck guides 102 interfering with the container 104. Thus, in the instance where a container becomes jammed or stuck in the conveyance system according to the present invention, the container can be removed from above the conveyance system without the necessity of having drop zones for bottles to be displaced, and without dumping a number of containers below the conveyance system.

[00035] Furthermore, when the neck guides are spread by an amount sufficient to allow for container removal, the containers can be directly retrieved or removed for subsequent processing. As will be apparent to persons skilled in the art, the vertical removal of containers according to the present invention is not possible with prior art systems that have a large plenum above the containers. The invention thus includes, not only an apparatus for conveying containers, but a method for conveying containers on an apparatus according to the invention.

Further, the invention includes methods of removing a container from a conveyance system of the invention that would not be possible with prior art systems.

[00036] Thus, the present conveyance system offers multiple means for supporting and moving containers not achievable with prior art pneumatic systems. Other systems for supporting and/or moving containers can be envisaged by persons of ordinary skill in the art in light of the present teachings. Thus, the

present invention contemplates use of other container removal and retrieval systems in conjunction with the presently described conveyance system.

[00037] For example, another exemplary embodiment of the invention provides a method for removing containers by replacing the body plenum 120 with articulating side guides. The articulating side guides are connected to actuators. With reference to Fig. 1, the side guide would occupy the position of the body plenum 120 and the actuators for articulating the side guides would be substituted for the body plenum supports 122. In using this embodiment of the conveyance system 100, in a stage of the container removal process, the side guide actuators are activated, moving the side guides toward the container and contacting the container or row of containers in order to grip and support the containers. The neck guides 102 can then be spread to allow for container removal (see Figs. 4-5), the side guides can then be raised or lowered by the actuators or another set of actuators in order to raise or lower the container for vertical removal from the conveyance system. In such an embodiment, the base plate and/or associated actuators need not be present.

[00038] Ill another exemplary embodiment, the containers can be removed from the conveyance system by use of a vacuum plate. In this embodiment, the vacuum plate is positioned above the container and between the neck guides 102. When removal of the containers is desired, the vacuum plate can be lowered to the container, contacting the opening at the top of the neck 114. A vacuum can them be applied to hold the container against the vacuum plate, thereby supporting the container when the neck guides 102 are spread for vertical (upward or downward) removal of the container. This embodiment also does not require that the base plate and/or associated actuators be present.

[00039] In yet another embodiment, the base plate 118 can comprise a belt conveyance system. In such an embodiment, after the container is resting on the belt of the base plate 118 (See Figs. 4-6), the neck guides 102 are spread and the container can continue to other processing steps by the belt conveyance system. The neck guides 102 need not open wide enough to allow vertical removal of the containers; nor is it necessary that the base plate 118 be extended so that the container neck is above the plenum 110. Further, as will be recognized, where the base plate comprises a belt or other conveyance system, the

belt need not be present at all points along the conveyance system, but only at the end where the bottles are off-loaded.

[00040] In yet other embodiments, containers can be removed from a side exit system, for example a robotic arm or other mechanical means. hi such embodiments, the body plenum 120, if present, may be movable in an vertical direction to allow access to the containers from a lateral direction. Alternatively, the base plate 118 and base plate actuators 210 may be designed to allow for a lowering of the containers after the neck guides 102 are widened. Lowering the base plate provides an alternative means to lateral access by a robotic arm or other removal means.

[00041] A system that can efficiently convey containers during manufacture and processing that is not subject to jams an resultant downtime and allows for simplification of retrieval, removal and loading systems is thus provided. The system operates with increased simplicity by not relying on moving containers to a secondary handling system for removal and replacement.

The inventive system is flexible, allowing initiation of removal and/or replacement of containers from the top or the bottom of the system. The system is compact, allowing it to fit in the same footprint as existing systems.

[00042] The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the inventors to make and use the invention. Nothing in this specification should be considered as limiting the scope of the present invention. All examples presented are representative and non-limiting. The above-described embodiments of the invention may be modified or varied, without departing from the invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the invention may be practiced otherwise than as specifically described.