The present application relates to a helical wrapping infeed device, and a helical wrapping system comprising said infeed device.

Helical wrapping apparatuses are known in the field as being versatile and efficient means of wrapping various articles. Typically, a rotating ring, to which one or more film rolls are attached, circles a conveyor on which the articles to be wrapped are placed. A free end of the film may be attached to, or engaged with, the articles. As the ring rotates, film from the film rolls is dispensed, around the articles, to wrap the articles.

Difficulties may be encountered when certain articles are wrapped using the aforementioned apparatuses.

It is an object of the present invention to mitigate or obviate at least some of the disadvantages associated with existing apparatuses and methods, whether mentioned in this document or otherwise.

According to a first aspect of the invention there is provided a helical wrapping apparatus infeed device for transporting a collation of articles towards a helical wrapping apparatus, the infeed device comprising: a base conveyor engageable with a base of the collation of articles and configured to transport the collation of articles towards the helical wrapping apparatus; and at least one support conveyor, engageable with a different face of the collation of articles to that of the base, configured to support the collation of articles during transportation of the collation of articles towards the helical wrapping apparatus.

Infeed device refers to a device which guides collations of articles towards the helical wrapping apparatus. The infeed device may guide collations of articles to the helical wrapping apparatus. The infeed device may be disposed at least partially within the helical wrapping apparatus. The infeed device may guide collations to, and through, the helical wrapping apparatus. At least a portion of the infeed device may penetrate the helical wrapping apparatus. The helical wrapping apparatus infeed device may be directly upstream of the helical wrapping apparatus. The helical wrapping apparatus may be configured to dispense a film to wrap the collation of articles. The film may be dispensable by the helical wrapping apparatus. As the helical wrapping apparatus rotates, the film may be dispensed. The film may be tensioned such that the film is configured to exert a force upon the collation of articles.

The transportation of collations of articles may otherwise be referred to as moving, or guiding, the collations. The collation of articles may be said to be transported along a longitudinal axis. The collations of articles may be said to be transported in a direction of travel e.g. from an upstream location to a downstream location.

Collations of articles refers to a grouping of articles. The collation comprises a plurality of articles. In the collation, the articles may be aligned, or grouped, to facilitate packing and/or shipping. The articles may be bottles, cartons or some other variety of container or packaging. The use of the at least one support conveyor may be particularly advantageous when the articles are at least partially flexible, such as the case for plastic bottles. There may be a gap in front of and/or behind the collation of articles. That is to say, the collation may refer to a group of articles which have been separated from a continuous line of articles.

The base conveyor may be referred to as a bottom conveyor, or a lower conveyor. The collations of articles may be said to rest on, or be supported by, the base conveyor. The base conveyor may be said to be configured to engage the base of the collation of articles. The base of the collation of articles may refer to a lowermost surface of the articles. Alternatively, the base of the collation of articles may refer to a separate component, such as a cardboard tray.

The at least one support conveyor may be substantially the same as the base conveyor, but be provided in a different orientation. The at least one support conveyor may engage a side of the collation of articles. That is to say, the at least one support conveyor may engage a side of the collation of articles which is substantially perpendicular to the base of the collation of articles. The at least one support conveyor may be said to grip, or structurally support, the collation of articles. Specifically, the at least one support conveyor may be said to grip, or structurally support, each of the articles forming the collation of articles. The at least one support conveyor is advantageously disposed to engage the different face of the collation and exert a supporting force thereupon. The supporting force exerted by the at least one support conveyor may be in a direction which generally opposes a direction of a force exerted upon the collation by the film dispensed by the helical wrapping apparatus.

The conveyors comprise a supporting surface. The supporting surface may be a belt. It will be appreciated that any reference to movement of the conveyors refers to movement of the supporting surfaces thereof specifically. The conveyors may be belt driven. The belt material of the conveyors may be a thermoplastic polyurethane base material, with a protective acrylic lacquer. Alternatively, a silicone or rubberised surface belt may be used. Desirable properties of the belts include high grip in wet conditions, high strength and high durability. The conveyors may operate at a speed of between around 0.1 m/s and around 0.25 m/s. More specifically, the conveyors may operate at a speed of between around 0.13 m/s and around 0.22 m/s. The conveyors may operate at a speed of around 0.185 m/s.

The base conveyor and the at least one support conveyor may be aligned with one another. That is to say, the conveyors may extend in the same, or substantially the same, direction. The direction may be the direction of travel. The base conveyor and the at least one support conveyor may be disposed generally perpendicular to one another.

By providing the at least one support conveyor, the collations of articles are supported on at least one further face beyond that of, and in addition to, the base. This is beneficial because, as the helical wrapping apparatus operates, the tensioned film which wraps the collations of articles may otherwise deform the articles. This risks damage to the articles, and an ineffective wrapping of the collation of articles. Ineffective wrapping of the collations may result from the film being applied to a deformed article which subsequently returns to its original, and undeformed, shape, thereby distorting the film. Providing the at least one support conveyor means that the articles, and so collations of articles, are more robustly supported and so the articles, and collations of articles, are not significantly deformed by the helical wrapping apparatus. This avoids the aforementioned problems of deformation, and associated poor quality wraps resulting therefrom, and the resulting wrap of the collations of articles is therefore improved. The claimed invention is also particularly advantageous when used with articles which are relatively deformable, such as plastic bottles and cartons (as opposed to relatively rigid articles, such as paint tins). When the articles leave the infeed device they are arranged in collations, ready for wrapping by the helical wrapping apparatus. The one or more support conveyors maintain the arrangement (e.g. alignment and/or orientation) of the collation through at least part of the helical wrapping process, whilst avoiding the articles in the collation becoming damaged due to excessive deformation. Put another way, the helical wrapping apparatus infeed device maintains the alignment and/or orientation of the collation of articles where the collation is arranged upstream of the helical wrapping apparatus (i.e. before a wrap is applied). The helical wrapping apparatus infeed device thereby supports, and maintains, the collation through at least part of the helical wrapping process.

The incorporation of the at least one support conveyor may also not require any modification to the helical wrapping apparatus. As such, existing helical wrapping systems can be modified to incorporate the improved infeed device, without significant difficulty or expense, to benefit from the aforementioned advantages.

The base conveyor and the at least one support conveyor may be simultaneously engageable with the collation of articles.

Simultaneously engageable means, for example, that the base of the collation of articles may engage the base conveyor whilst the side of the collation of articles engages the at least one support conveyor. In other words, the collation of articles is supported in multiple directions for at least a portion of the distance the collation is transported by the infeed device.

The collation of articles may be simultaneously engageable by the base conveyor and the at least one support conveyor for the entire distance the collation of articles are transported by the infeed device. Alternatively, the collation of articles may only be simultaneously engageable by the base conveyor and the at least one support conveyor for a portion of the distance the collation of articles is transported by the infeed device. This may be the case where, for example, one of the base conveyor and the at least one support conveyor extends beyond the other. Simultaneous engagement of the collation of articles by the base conveyor and the at least one support conveyor may otherwise be expressed as there being an overlap of the base conveyor and the at least one support conveyor. That is to say, the base conveyor and the at least one support conveyor may overlap one another along a longitudinal axis defined in a direction of travel of the collations of articles.

The simultaneous engagement advantageously means the collations of articles are simultaneously supported on multiple faces. This improves the stability of the collation of articles, and reduces the risk of undesirable movement and/or deflection of the collation or articles thereof. This, in turn, improves the quality of the wrap applied by the helical wrapping apparatus.

The at least one support conveyor may extend beyond the base conveyor, towards the helical wrapping apparatus. The at least one support conveyor may extend along a longitudinal axis.

The at least one support conveyor may extend beyond the base conveyor because the base conveyor is shorter than the at least one support conveyor. Alternatively, the conveyors may be the same, or similar, lengths, but be disposed at different longitudinal positions along the infeed device.

The longitudinal axis may correspond with, or align with, a direction of travel of the collation of articles.

Advantageously, where the at least one support conveyor extends beyond the base conveyor, and where a base wrap of film is applied to the collation of articles beyond the base conveyor, the base wrap is contained within the helical wrap applied by the helical wrapping apparatus. This means the base wrap is not externally exposed, owing to the helical wrap providing an encapsulating outer wrap. That is to say, the base wrap is contained within the outer wrap applied by the helical wrapping apparatus. This is also achieved while the collation is still supported by the at least one support conveyor, and the structural integrity of the collation, and articles, is therefore also maintained (along with the quality of the wrap). Where the base wrap is applied under tension, the base wrap advantageously contracts when applied to the collation, urging the articles into close proximity with one another.

The base conveyor may be disposed substantially horizontally.

The base conveyor being disposed substantially horizontally is advantageous because the collations of articles are more readily supported. The risk of articles falling from the base conveyor may also be reduced as a result of the this orientation of base conveyor.

The at least one support conveyor may comprise a plurality of support conveyors.

Any of the features mentioned above or below in connection with the at least one support conveyor are equally applicable to either, or both, of the plurality of support conveyors.

The plurality of support conveyors may comprise a pair of support conveyors, and each of the pair of support conveyors may engageable with a different face of the collation of articles.

Each of the pair of support conveyors may be substantially identical to one another. That is to say, the support conveyors may have the same dimensions, for example.

At least one of the pair of support conveyors may engage a side of the collation of articles.

It will be appreciated that the term face is used to refer to what is an effective face. That is to say, the collation of articles is unlikely to have, for example, a perfectly planar face owing to the fact that the collation is formed of multiple individual articles. Face is, in this context, used to refer to a surface by which the collation of articles can be supported.

The pair of support conveyors may oppose one another. The pair of support conveyors opposing one another may be expressed as the pair of support conveyors being in facing relations with one another.

The pair of support conveyors opposing one another may facilitate the support of a collation of articles by the support conveyors.

When considered in combination with the base conveyor, the pair of conveyors may be said to define a U-shaped guide. That is to say, the pair of conveyors may engage opposing faces of the collation of articles. Advantageously each of the three conveyors engages a different face of the collation of articles, which is preferably a base and two sides extending therefrom.

A top conveyor may also be incorporated in some embodiments. The top conveyor may be a driven conveyor. The top conveyor may oppose the base conveyor. The top conveyor may be configured to engage an upper face of the collation. Where a top conveyor is incorporated, along with two support conveyors and the base conveyor, the conveyors may define a generally square, or rectangular, guide. That is to say, the conveyors may generally surround the collation by forming a loop therearound. Four conveyors may be said to generally encircle, or enclose, the collation. The four conveyors may each engage a different face of the collation of articles, which is preferably a base, top, and two sides extending therebetween.

The at least one support conveyor may be disposed substantially perpendicular to the base conveyor.

Where a pair of support conveyors are incorporated, the combination of the pair of support conveyors and the base conveyor may define three sides of a square when viewed in cross-section along the longitudinal axis or the direction of travel. Where the at least one support conveyor comprises a pair of support conveyors, each one of the pair of support conveyors may be disposed substantially perpendicular to the base conveyor. That is to say, the combination of the three conveyors may generally define an open square. Where a top conveyor is also incorporated, the combination of four conveyors may generally defined a square. The base conveyor and the at least one support conveyor may be operable at substantially the same speed.

Same speed in this instance is intended to mean linear speed. That is to say, a speed determined by the displacement of a point on a supporting surface of the conveyor, in a given time, during operation of the conveyor(s).

By operating at the same speed, the conveyors advantageously support the collation of articles in the orientation in which the collation arrives at, or is engaged by, the conveyors. Advantageously this means the individual articles in the collation can be wrapped in a preferred arrangement, or collation.

Each of the plurality of support conveyors may comprise a pair of belts.

The pair of belts associated with each support conveyor may be disposed adjacent one another. Each support conveyor may be said to comprise a plurality of belts. The pair of belts may be longitudinally arranged relative to one another.

By providing a pair of belts, a supporting surface of the support conveyor proximal the collation of articles may move in the same direction as a supporting surface distal the collation of articles. In other words, inner and outer surfaces of the belts may be synchronised and move in the same direction. This may be desirable where the support conveyor extends into a helical wrapping zone, and film is (temporarily) applied to an outer surface of the support conveyor. If the inner and outer surfaces were moving in opposite directions (i.e. if a single belt was used), the wrap may be urged in opposite directions by the different surfaces, leading to a poor quality wrap.

The pair of belts may be arranged in a layered manner. Each of the pair of belts may be arranged generally in a lozenge shape e.g. a rectangle with rounded ends.

Each of the pairs of belts may be driven by spur gears which are engageable with a common motor.

Each of the pairs of belts may be driveable by the common motor. The common motor may be an AC or DC motor. By driving the pair of belts with the common motor, the number of motors required in order to use the infeed device is advantageously reduced. In turn, associated energy usage, costs and cooling requirements are also reduced.

By driving the pair of belts with the common motor, the speed and direction of travel of the belts can be synchronised. Furthermore, the spur gears can be used to, for one of the belts, reverse the direction of rotation of motor output. One motor may be provided to drive each conveyor. Alternatively, multiple conveyors may be driven by the same motor. The synchronised start, stop and acceleration of the pairs of belts is also a further advantage resulting from the pair of belts being driven by a common motor.

The infeed device may further comprise a feed conveyor upstream of the base conveyor, and wherein loose articles are receivable at an upstream end of the feed conveyor.

The feed conveyor may be wider than the base conveyor. That is to say, the feed conveyor may be able to support articles in a greater variety of orientations. The feed conveyor may also be axially longer than the base conveyor.

The feed conveyor may be operated at the same speed as the base conveyor. This may enable the articles supported on the feed conveyor to transition to being supported by the base conveyor more easily. The feed conveyor may be aligned with the base conveyor. Respective supporting surfaces of the feed conveyor and base conveyor may be substantially coplanar with one another. The feed conveyor and the base conveyor may extend in substantially the same direction.

Upstream of the base conveyor is intended to mean in a direction which opposes the direction of travel.

Loose articles may include articles which are uncollated and/or unsorted. Uncollated articles may refer to articles which are not arranged in desired collations (e.g. a grouping of four, aligned, articles). Uncollated articles may refer to articles which have already been sorted such that the articles are all aligned in a common direction (but which have not yet been grouped into collations of articles). Unsorted articles may refer to articles which are randomly placed, owing to the articles not having been sorted into a desired alignment.

The infeed device may further comprise collation means disposed along the feed conveyor, wherein the collation means is configured to arrange the articles into the collations of articles.

Arranging the articles into collations is desirable because it is more efficient to group articles for wrapping and shipping. Being configured to arrange articles into collations may otherwise be expressed as being configured to collate articles.

The collation means may be disposed along the feed conveyor such that uncollated and/or unsorted articles which are placed on an upstream end of the conveyor are subsequently grouped into collations of articles before reaching a downstream end of the feed conveyor.

The collation means may be referred to as a retention means.

The collation means may be a clamp arrangement which comprises a plurality of clamps.

The plurality of clamps is a simple and effective collation means. The clamping means can be sized, axially, such that the clamping means engages one or more (e.g. 100) articles. For example, the clamping means may have an axial length which is long enough to engage the sides of four articles. In such case, the clamping means will grip four articles in use.

A constant flow of aligned articles may be provided to the clamping means. The clamping means may periodically operate to engage one or more articles to effectively suspend, or hold, those articles whilst the feed conveyor continues to run. Whilst the feed conveyor operates at a constant speed, engaging the one or more articles may temporarily grip the engaged articles whilst the supporting surface of the feed conveyor (e.g. a belt) continues to move beneath the engaged articles. A corresponding gap may therefore be formed between the downstream collation of articles and a front article of the gripped articles (i.e. a leading article), owing to the engaged articles being “suspended” (e.g. such that the supporting surface of the feed conveyor moves relative to the engaged articles. Put another way, the leading article prevents the downstream travel of the articles queued behind the lead article. The clamping means subsequently disengage, after a desired gap has been formed, and allows a desired number of articles to pass through the clamping means. After the desired number of articles have passed through the clamping means, all behind the previous leading article, the clamping means operates to grip at least a new lead article. A new gap then forms, and the previously gripped articles are considered to have formed a collation (with a gap in front and behind the collation). The process continues, on loop, to form the next collation. As described elsewhere, the collation is then wrapped. The wrapped collation may be considered to be a pack.

As an alternative to a clamp arrangement, the collation means may comprise a stop plate (push-up stop or side retention plate) to restrict the forward movement of the lead article. Any other means of preventing downstream travel of the lead article may otherwise be employed.

The clamps may be pneumatically operable.

The clamps may otherwise be hydraulically or electrically operable.

The infeed device may further comprise sorting means configured to align articles on the feed conveyor upstream of the collation means.

By aligning articles on the feed conveyor, the base conveyor can be made narrower than the feed conveyor. This is because the articles, which are initially unsorted, are arranged into a preferred alignment by the sorting means. A narrower base conveyor is advantageous because the film applied by the helical wrapping apparatus is less affected by the presence of the base conveyor. That is to say, the wrapped collation of articles can be made more compact when the base conveyor is narrower. The relatively narrower base conveyor also enables the wrap to bind to both the collation and the base conveyor. This provides improved pack stability (i.e. wrapped collation stability) once the base conveyor is removed (i.e. downstream of an end of the base conveyor). Aligning the articles is desirable because this facilitates efficient packing and shipping of the articles. For example, if four articles are grouped, but the articles are not in a uniform alignment, the resulting collation may be unnecessarily large. Furthermore, a non-uniform alignment may also result in an unnecessarily loose wrapped collation, or pack.

The collation means may, for example, rotate the articles through a given range of motion. The range may be, for example, around 90°. The articles may be pivoted by the sorting means.

Alternative examples of sorting means include a bump turner and curved feed guide.

The sorting means may comprise a sorting wheel, and wherein the sorting wheel comprising a plurality of projections.

The sorting wheel can be operated using a motor. The sorting wheel can be used with a variety of different articles to sort said articles into a preferred, and uniform, alignment. The sorting wheel can also be used to sort articles more swiftly than, for example, an alternative pick-and-place system or mechanism. Alternatively, the sorting wheel may be passive. That is to say, the sorting wheel may not be actively driven by a shaft and may instead be driven by a pressure of the articles as the articles engage the sorting wheel under the motion of the feed conveyor.

A bumper may cooperate with the sorting wheel to guide the articles through a desired range of motion, or movement. The bumper may be arcuate.

In other embodiments the sorting means may comprise a bump turner. Alternatively, the sorting means may be omitted in its entirety.

According to a second aspect of the invention there is provided a helical wrapping system for wrapping collations of articles, the system comprising: an infeed device according to the first aspect of the invention; a helical wrapping apparatus configured to helically wrap the collations of articles with a film; and a downstream conveyor configured to transport wrapped collations of articles away from the helical wrapping apparatus.

The helical wrapping system may otherwise be referred to as a helical wrapping assembly or arrangement.

The helical wrapping apparatus may be disposed between the infeed device and the downstream conveyor. However, it will be appreciated that the helical wrapping apparatus need not be provided directly between the infeed device and downstream conveyor. The helical wrapping apparatus may instead be provided partway along one of the infeed device and the downstream conveyor. Put another way, part of the infeed device or downstream conveyor may extend into, or penetrate, the helical wrapping apparatus. Advantageously the infeed device at least partially penetrates the helical wrapping apparatus to support the collation of articles during wrapping. Penetration of the helical wrapping apparatus may refer to part of the infeed device extending, or projecting, into an aperture, or bore, defined by the helical wrapping apparatus.

The film used to wrap the articles may be a linear low density polyethylene stretch film substrate. Other materials, with similar stretch properties, may otherwise be used. Low density may refer to a density of between around 900 kg/m ³ and around 1000 kg/m ³ . More specifically, low density may refer to a density of between around 915 kg/m ³ and around 925 kg/m ³ .

Downstream of the helical wrapping apparatus, a cutting apparatus may be provided to separate the film between the collations of articles. The cutting apparatus may comprise a blade, crimper, hot wire, laser, ultrasound device or other mechanical device of some variety.

The downstream conveyor may be aligned with the infeed device to define a single direction of travel through the helical wrapping apparatus. The downstream conveyor may be referred to as an outfeed conveyor.

The helical wrapping apparatus can advantageously be used to efficiently wrap collations of articles in a variety of shapes and sizes. The at least one support conveyor of the infeed device advantageously supports the articles forming the collation of articles whilst the film is applied. The film may dispensed by the helical wrapping apparatus by virtue of frictional engagement with the articles. As such, whilst the film is dispensed a force may be exerted upon the articles, by the film, which could deform articles which are at least partly flexible (such as, for example, plastic bottles). Undue deformation of the collation, resulting from the application of the aforementioned force, can lead to a poor quality wrap. This may be due to, for example, the articles “springing back” to their undeformed state after the film has been applied. The at least one support conveyor ensures the articles remain more robustly supported during application of the film, resulting in an improved quality wrap. The application of the film may also risk the misalignment of the collations of articles. That is to say, the collation of articles may end up becoming at least partly uncollated due to the force exerted by the film. The overall collation may also become twisted due to the force exerted by the film. The support conveyor also assists in this regard, ensuring the collation remains aligned as desired before, and during, the application of the film (i.e. the wrapping of the collation).

The infeed device may be directly upstream of the helical wrapping apparatus. That is to say, articles may be pass straight from the infeed device to the helical wrapping apparatus.

The helical wrapping apparatus may be configured to helically wrap the collations of articles with a film in a helical wrapping zone.

The helical wrapping apparatus may comprise a rotatable annulus with one or more film rolls mountable thereto, the film being dispensable by the one or more film rolls, and wherein a longitudinal extent of the film rolls defines a helical wrapping zone.

The rotatable annulus may be of the form of a ring. The rotatable annulus may be movable mounted to a fixed mount. The base conveyor and/or at least one support conveyor or downstream conveyor may penetrate the rotatable annulus. The rotatable annulus may be driven by a motor so as to rotate around an axis defined in the direction of travel of the articles. One film roll may be mounted to the rotatable annulus. Alternatively, two or more film rolls may be mounted to the rotatable annulus. Where two film rolls are mounted to the rotatable annulus, the film rolls are advantageously mounted at diametrically opposing positions on the annulus. The film rolls may be replaceable once the film dispensed thereby has run out. A plurality of films rolls may be mounted to a corresponding plurality of film roll mounts. Where employed, a plurality of film mounts may be mounted at circumferentially equidistant positions on the annulus.

One or more tensioners may be interpose the film roll and the collation of articles. The film rolls may generally extend in the direction of travel. That is to say, the film rolls may generally align with the conveyor(s).

The longitudinal extent of the film rolls may be a length of the film rolls in the direction of travel. That is to say, where the film roll is generally cylindrical, the longitudinal extent refers to the height of the cylinder (i.e. the axial length through which the circular cross-section extends). When placed on a flat surface, end-on, the length of the film roll is the height to which the roll extends from the flat surface. In an alternative definition, the length of the film roll may refer to the unwound length of the film, and the longitudinal extent of the film roll may be referred to as a width of the film roll. Using such definition, the film roll may be between around 100 mm and around 400 mm wide. More specifically, the film roll may be between around 125 mm and around 300 mm wide. The film roll may be around 250 mm wide. The longitudinal extent of the film roll may be at least equal to a width of one article. The longitudinal extent of the film roll may be at least equal to a width of two articles.

A free end of the film may engage the collation of articles. The film may be dispensed by rotation of the rotatable annulus. Rotation of the annulus may unwind the film from the film roll, the film subsequently being applied to the collation.

The helical wrapping zone refers to a zone in which the film is applied to the collation. Specifically, the helical wrapping zone is a zone in which the film is actively applied to the collation (e.g. in which the film is being dispensed by the film roll and applied to the collation). A length of the zone, in the axial direction, may be defined by the length of the film roll(s). The at least one support conveyor may extend at least into the helical wrapping zone.

The at least one support conveyor may extend past the helical wrapping zone. The at least one support conveyor may overlap the downstream conveyor in the direction of travel.

The at least one support conveyor may be said to penetrate the helical wrapping zone. In other words, the at least one support conveyor may project into the helical wrapping zone. The collation is therefore advantageously supported by the at least one conveyor whilst the film is applied by the helical wrapping apparatus.

The at least one support conveyor may penetrate the helical wrapping apparatus by projecting into an aperture, or bore, defined thereby.

The at least one support conveyor may, in effect, transition the collation from the base conveyor to the downstream conveyor. The at least one support conveyor may be said to deliver, or transport, the (wrapped) collation to the downstream conveyor. The at least one support conveyor may be said to provide a generally seamless transition of the collation from the base conveyor to the downstream conveyor. The at least one support conveyor may be said to deliver, or transport, the (wrapped) collation to the downstream conveyor. The at least one support conveyor may extend up to the downstream conveyor. The at least one support conveyor may be provided directly upstream of the downstream conveyor.

The film may be configured to engage a portion of the at least one support conveyor and the collation of articles.

Advantageously, after the film disengages the conveyor the film may contract. The film may therefore tighten around the collation. The conveyors may therefore, in effect, be configured to tension the film. The conveyors can therefore be said to provide a tensioning functionality to the film. The film may be said to spring back around the collation upon disengaging the conveyor(s).

Described another way, the at least one support conveyor may be at least partially, and temporarily, wrapped with the collation. The base conveyor may extend at least into the helical wrapping zone.

The base conveyor may extend past the helical wrapping zone. The base conveyor and downstream conveyor may be interposed by the helical wrapping apparatus.

The system may further comprise articles comprising bottles.

The bottles may be plastic.

The collation of articles may comprises two, three four, or five bottles.

The bottles may be arranged in a 4x1 arrangement. That is to say, the collation may be formed of four bottles adjacent one another (i.e. four bottles long and one bottle wide, or a line of four bottles). Alternatively, the bottles may be arranged in a 5x1 arrangement, or a 4x2 or 5x2 arrangement.

The collation may comprise a line of single-file articles (i.e. in an Xx1 arrangement). Alternatively, the collation may comprise a plurality of rows of articles (i.e. in an Xx>1 arrangement). For example, the collation may be of a 5x2 arrangement in which two rows of articles extend by 5 articles in length. That is to say, there may be multiple articles wrapped side-by-side in the collation.

The collation of articles may comprise a plurality of bottles.

The optional and/or preferred features for each aspect of the invention set out herein are also applicable to any other aspects of the invention, where appropriate.

Specific embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 is a perspective view of a helical wrapping system, with four articles provided thereon, according to an embodiment of the invention; Figure 2 is a perspective view of a helical wrapping apparatus infeed device, with four articles provided thereon, forming part of the helical wrapping system of claim 1;

Figure 3a is a plan view of part of the helical wrapping apparatus infeed device, and articles, shown in Figure 2;

Figure 3b is an end view of the infeed device, and articles, shown in Figure 3a;

Figure 4 is a perspective cutaway view of the helical wrapping system, and articles, shown in Figure 1;

Figure 5 is an isolated perspective view of a helical wrapping apparatus forming part of the helical wrapping system shown in Figure 1;

Figure 6a is a side view of the helical wrapping system showing Figure 1 ;

Figure 6b is a plan view of the helical wrapping system of Figure 1 ;

Figure 6c is a section view of the helical wrapping system of Figure 1;

Figures 7a-f schematically illustrate various stages of a setup process of the helical wrapping system shown in Figure 1 ; and

Figures 8a-c schematically illustrate various stages of a run-out process of the helical wrapping system shown in Figure 1.

Figure 1 is a perspective view of a helical wrapping system 2 according to an embodiment of the invention.

The helical wrapping system 2 comprises an infeed device 4, a helical wrapping apparatus 6 and a downstream conveyor 8. As shown in Figure 1, a housing 10 generally encloses the downstream conveyor 8, the helical wrapping apparatus 6 and a portion of the infeed device 4. Also shown in Figure 1 is a collation of articles 12. The collation 12 comprises four articles 12a-d which, in the illustrated embodiment, are milk bottles.

In use, articles 12a-d are received by the helical wrapping system 2 at an upstream end of the infeed device 4, indicated generally by the letter A. The articles 12a-d are transported by the infeed device 4 towards the helical wrapping device 6 where the articles 12a-d are wrapped together using a film. Whilst the articles 12a-d are transported, they are first aligned and are then grouped into a collation 12. At the point where the articles 12a-d are wrapped, the articles 12a-d are in the form of a collation 12 of articles as shown in Figure 1. That is to say, the articles 12a-d have been aligned and grouped into a collation 12.

The wrapped collation 12 is then transported away from the helical wrapping apparatus 6 by the downstream conveyor 8. The wrapped collation 12 may subsequently be separated, by some form of cutting means, into a plurality of wrapped collations. This will be described in detail below. A wrapped collation may be referred to as a pack.

The articles 12a-d are therefore transported in a direction of travel, indicated by the arrow 14.

The infeed device 4 comprises a base conveyor 16 (not visible in Figure 1) and a pair of support conveyors 18a, 18b (also not visible in Figure 1). The base and support conveyors 16, 18a, 18b will be described in detail in connection with Figure 2 onwards.

Returning to Figure 1, the infeed device 4 further comprises a feed conveyor 20, a collation means 22 and a sorting means 24.

Briefly, in the illustrated embodiment the feed conveyor 20 is disposed upstream of the base conveyor 16. That is to say, articles 12a-d first pass along the feed conveyor 20 before passing along the base conveyor 16. Along the feed conveyor 20 the collation means 22 is provided. In the illustrated arrangement the collation means 22 is in the form of a pneumatically operable clamping arrangement. In other embodiments, the collation means 22 may take other forms including, for example, an electronically operable clamping arrangement. Alternatively, the collation means may be omitted in its entirety. The clamping arrangement 22 periodically operates to grip a plurality of articles 12a-d whilst the feed conveyor 20 continues to run. When gripped, the articles 12a-d may be referred to as lead articles in a line of articles (see, for example, Figures 7c and 7c). As the feed conveyor 20 continues to run, a gap is created between a first (i.e. front) article of the gripped articles and a last (i.e. end) article of a downstream collation of articles. The collation of articles may therefore refer to a group of articles that have been separated from a continuous line of articles into a desired arrangement, or grouping. More generally, a collation of articles may refer to a plurality of articles. There may be a gap in front of and/or behind the collation of articles. The period of time for which the clamping arrangement 22 is open (e.g. such that articles can pass therethrough) determines how many articles are grouped into the collation of articles (downstream of the “gripped” articles when the clamping arrangement 22 subsequently grips the next set of articles). This is owing to the fact that the time period for which the clamping arrangement 22 is open, or disengaged, determines how many downstream articles can continue to move forward on the feed conveyor 20, past the clamping arrangement 22 (and subsequently form the collation). Any number of articles may be included in the collation depending on how long the clamping arrangement 22 is disengaged, or in a disengaged state. Whilst the illustrated clamping arrangement 22 is configured to engage four articles, it will be appreciated that only one article need be engaged (so as to prevent passage of articles behind the gripped article).

Sorting means 24 is in the form of a sorting wheel. The sorting means 24 is used to align the loose articles which are received at an upstream end A of the feed conveyor 20. The sorting means 24 thereby sorts, or aligns, articles. This is in contrast to the collation means 22, which groups aligned articles 12a-d into collations 12. The sorting means 24 may otherwise comprise one or more alternative mechanisms, such as one or more bump turners, scrolls, curved guide rail assemblies or robot pick and place systems. The sorting means may otherwise be referred to as a rotation means. This may be because the sorting means provides a rotation functionality in that it rotates the articles as they pass through, or across, the sorting means. In the illustrated embodiment the sorting means 24 rotates the articles by around 90°. This is in order to align the articles in a preferred orientation before the articles are collated into a collation of articles, upstream of the wrapping apparatus. The present invention relates to the infeed device 4, and specifically to the arrangement just upstream of the helical wrapping apparatus 6.

Figure 2 is a perspective view of a portion of the infeed device 4. In Figure 1 , most of the portion of the infeed device 4 shown in Figure 2 is obscured by the housing 10 (said portion being located just upstream of the helical wrapping apparatus 6).

Figure 2 also shows the base conveyor 16 and first and second support conveyors 18a, 18b. Part of the feed conveyor 20 is also shown upstream of the base conveyor 16. Although not shown in the illustrated embodiment, in other embodiments a top conveyor may also be incorporated. The top conveyor may generally oppose the base conveyor. The top conveyor may be configured to engage an upper face, or top side, of the collation of articles. The top conveyor may be a driven conveyor. The specific arrangement of conveyors may be dependent upon the articles to be supported and wrapped.

Like Figure 1, Figure 2 also shows the collation of articles 12 being transported by the infeed device 4 in the direction of travel 14.

In use, a base (e.g. an underside) of the articles 12a-d is supported by the base conveyor 16. That is to say, the base of each of each of the articles 12a-d, or the collation 12, engages the base conveyor 16. When the base conveyor 16 is operated, the base conveyor 16 transports the collation 12 of articles towards the helical wrapping apparatus 6 (not shown in Figure 2).

Throughout this document, references to the conveyors 8, 16, 18a, 18b, 20 (downstream conveyor 8 not shown in Figure 2) operating refers to a surface of the conveyors moving. Each of the conveyors may be belt driven, in which case references to operation of the conveyor refer to instances when a respective belt, or belts, is driven so as to move a supporting surface on which the articles 12a-d rest. The movement may be linear. The movement may be described as a rolling movement, owing to the belt(s) rolling over a plurality of rollers or pulleys during operation. In use, the conveyors are operated to transport articles towards, or away from, the helical wrapping apparatus. As the collation 12 is wrapped by the helical wrapping apparatus 6 (not shown in Figure 2), a film which is applied by the helical wrapping apparatus 6 may deform and/or cause the articles 12a-d to topple or become misaligned. This can be described as the collation 12 becoming uncollated. This is particularly prevalent when the articles are, as shown in Figure 2, milk bottles. By incorporating the first and second support conveyors 18a, 18b, the collation of articles 12 is more robustly supported during the wrapping process. This, is turn, provides an improved wrap due to reduced deformation of the articles 12a-d and by ensuring that the collation 12 remains collated (e.g. grouped) and/or aligned as desired.

A further problem which may be encountered is that a last, or trailing, article of a collation of articles may not be kept “tight”, or aligned, with the rest of the collation during the wrapping process. This may be owing to there being no upstream article engaging the trailing article to urge it through the helical wrapping apparatus and helical wrapping zone in close engagement with the rest of the collation. Employing the support conveyors 18a, 18b overcomes this issue by supporting even the final article during wrapping, resulting in a more tightly packed, and so desirable, collation.

Each of the base conveyor 16 and support conveyors 18a, 18b share a generally similar construction. Each of the conveyors comprises a frame, pair of belts and a fixed tip. The pair of belts is driven by a motor associated with each conveyor, referred to as a common motor.

Beginning with the base conveyor 16, the base conveyor 16 comprises a frame 26, first and second belts 28a, 28b and a fixed tip 30. The pair of belts 28a, 28b are arranged adjacent one another and are driven by a common motor 32. The first and second belts 28a, 28b are arranged adjacent one another such that inner and outer surfaces of the conveyor move in the same direction in use. Inner surface refers to a surface which is closest to the collation (e.g. that labelled 28a in Figure 2). Outer refers to a surface which is furthest away from the collation (e.g. that labelled 28b in Figure 2). A fixed plate may be provided between the first and second belts 28a, 28b to support any load transmitted through the first and second belts 28a, 28b. The plate may be covered, or coated, with a low friction material to allow the first and second belts 28a 28b to slide over the plate with low resistance. The design of the base conveyor 16 may be substantially identical to that of the support conveyors 18a, 18b, save for variations in width and length.

In use, the motor 32 is electrically powered and drives a corresponding output shaft. The output shaft drives the first and second belts 28a, 28b. The first belt 28a can be said to provide a supporting surface upon which the collation 12 rests in use. A given point on the upper side of the first belt 28a moves in the direction of travel 14 when the conveyor is driven. Similarly, a given point on an underside of the second belt 28b moves in the direction of travel 14 when the conveyor is driven. For the purposes of the base conveyor 16, the upper side may be referred to as an inner side. Similarly, the lower side may be referred to as an outer side.

A downstream end of the first belt 28a is proximate the fixed tip 30. The fixed tip 30 is a surface that the collation 12 traverses as the collation leaves, or disengages, the first belt 28a. The fixed tip 30 can be said to generally provide a stationary extension of the first belt 28a.

Turning to the first support conveyor 18a, as mentioned above the general arrangement is similar to the base conveyor 16. Accordingly, the first support conveyor 18a comprises a frame 34, first and second belts 36a, 36b and a fixed tip 38.

The first and second belts 36a, 36b associated with the first support conveyor 18a are again driven by a common motor. However, the common motor is not visible in Figure 2. The common motor for the first support conveyor 18a is visible in Figure 3b, indicated with numeral 56. The arrangement of the belts 36a, 36b in use is the same as that described above in connection with the base conveyor 16. That is to say, inner and outer surfaces of the belts 36a, 36b respectively move in the same direction in use.

Returning to Figure 2, the second support conveyor 18b is substantially identical in structure to the first support conveyor 18a. The second support conveyor 18b comprises a frame 40, a first belt 42a, a second belt 42b and a fixed tip 44. From the view shown in Figure 2, a common motor 46, which drives the first and second belts 42a, 42b, is also visible. Again, inner and outer surfaces of the belts 42a, 42b respectively move in the same direction in use. For all of the base conveyor and first and second support conveyors, 16, 18a, 18b, the inner and outer faces of the respective pairs of belts move in the same direction in use. This is advantageous when the film, applied by the helical wrapping apparatus, is at least partially applied around the conveyors 16, 18a, 18b. By moving in the same direction, the film is not urged away, or detached from, the collation by being forced in the opposite direction to the direction of travel 14 of the collation. This will be described in greater detail below.

Figure 2 also shows an upstream end of the feed conveyor 20, the upstream end being indicated with the numeral 20a.

Also visible in Figure 2 are a pair of guides 50a, 50b. Guides 50a, 50b comprise adjustable guide rails. The pair of guides 50a, 50b guide collated articles 12a-d downstream of the collating means 22 shown in Figure 1. The guides 50a, 50b, and guide rails forming part thereof, limit the lateral movement of articles 12a-d without resisting the movement of the articles 12a-d in the direction of travel 14.

In use, and as indicated by Figure 2, each of the base conveyor 16, and first and second support conveyors 18a, 18b engage a different face of the collation 12 of articles. As such, when all of the conveyors 16, 18a, 18b are operated at the same speed, the collation 12 of articles is supported on three different sides. This ensures the articles 12a-d, which make up the collation 12, remain aligned correctly and arranged in the collation 12, and prevents undue deformation of the articles 12a-d. As previously mentioned, this is particularly advantageous when the articles 12a-d are comparatively weak, or deformable, as is the case for the milk bottles shown in the appended Figures.

Although the illustrated arrangement comprises a pair of support conveyors 18a, 18b, in other arrangements only one support conveyor 18a, 18b may be provided. However, providing the pair of support conveyors 18aa, 18b, arranged in an adjacent manner as shown in Figure 2, advantageously supports two opposing faces of the collation 12.

It will be appreciated that references to a face, or side, of the collation 12 may otherwise refer to an effective face of the collation. The effective face of the collation may not be a continuous face owing to the fact that the effective face is defined by contributory faces of the individual articles which make up the collation.

Turning to Figure 3a, a plan view of the part of the infeed device 4 shown in Figure 2 is provided in isolation of the feed conveyor 20 and guides 50a, 50b.

Figure 3a shows a gearing arrangement 52 which is used to drive the first and second belts 36a, 36b associated with the first support conveyor 18a. The arrangement 52 comprises first and second spur gears 54a, 54b, which may otherwise be referred to as gears. Each of the spur gears 54a, 54b drives a respective first and second belt 36a, 36b. Only one of the spur gears 54a, 54b is directly driven by a common motor. The other one of the spur gears 54a, 54b is indirectly driven by the motor by virtue of the meshing engagement of the teeth of the spur gear 54a, 54b. Advantageously the meshing of the spur gears 54a 54b also means that the spur gears 54a, 54b rotate in opposing directions in use. By arranging the belts 36a, 36b as shown in Figure 3a, in combination with the opposing directions of rotation of the gears 54a, 54b, the inner surface of the first belt 36a (i.e. the surface which engages the collation 12 in Figure 3a) moves in the same direction as the outer surface of the second belt 36a (i.e. an exposed belt surface facing away from the collation 12).

In use, rotation of the spur gears 54a, 54b rolls the respective first and second belt 36a, 36b. In turn, by virtue of the operation of the belts 36a, 36b, and so the first support conveyor 18a more generally, the collation 12 is transported towards the helical wrapping apparatus.

Although not shown in Figure 3a, a like gearing arrangement 52 is provided in connection with the second support conveyor 18b. However, in Figure 3a that gearing arrangement is obscured from view by a cover plate 56a and a gearbox cover 56b. In Figure 2, respective plates and gearbox covers are provided over both gearing arrangements.

Turning to Figure 3b, an end view of the infeed device 4 is provided from a perspective opposite the direction of travel 14 as shown in Figure 2. This view shows, in more detail, a part of the assembly which may be referred to as a dynamic dead plate. The base conveyor 16 and first and second support conveyors 18a, 18b are also shown. The common motors 46, 56 associated with each of the first and second support conveyors 18a, 18b respectively are also visible in Figure 3b. The motor 32 which operates the base conveyor 16 is also visible in Figure 3b.

Figure 3b demonstrates how each of the base conveyor 16 and first and second support conveyors 18a, 18b engage a different face of the article 12a, and so collation 12. The article 12a is therefore engaged by a respective conveyor on three faces. The conveyors 16, 18a, 18b can therefore be said to be arranged in a U-shape. The conveyors 16, 18a, 18b can also be said to be distributed around the direction of travel 14. The conveyors 16, 18a, 18b are advantageously disposed perpendicularly to one another. The base conveyor 16 is disposed horizontally in the illustrated arrangement, and the support conveyors 18a, 18b are disposed vertically. However, it will be appreciated that other variations of positions of the conveyors 16, 18a, 18b may otherwise be utilised.

Figure 4 is a perspective view of the infeed device 4, helical wrapping apparatus 6 and downstream conveyor 8. Figure 4 may otherwise be described as the system 2 shown in Figure 1 with the housing 10 removed for ease of visibility.

At an upstream end of the arrangement, articles 12a-d are received at the collation means 22 having already been aligned by the upstream sorting means 24 (not visible in Figure 4, but shown in Figure 1). As previously explained, the collation means 22 is in the form of a clamp arrangement. The clamp arrangement comprises two clamps, which oppose one another. The collation means 22 intermittently operates so as to grip a plurality of articles 12a-d. This is achieved, in the illustrated arrangement, by the clamp arrangement 22 intermittently gripping a plurality of articles 12a-d whilst the feed conveyor 20 continues to operate (thereby creating a gap between the previous collation and the clamped articles 12a-d). When a gap has been formed, owing to the continuously operating feed conveyor 20, the gripped articles 12a-d are released to form a collation 12. In this instance, the articles 12a-d may be collated in a group of four articles 12a-d. The illustrated collation 12 is therefore a 4x1 arrangement i.e. four articles disposed adjacent one another in a single file line. It will be appreciated that various other collation arrangements are possible (e.g. a 4x2, or 5x2 arrangement). As previously mentioned, the period of time for which the clamp arrangement 22 grips the articles determines the gap. The period of time for which the clamp arrangement 22 is open, or in a disengaged state, determines the number of articles in the collation. This is owing to the fact that the feed conveyor 20 operates continuously, and independently of the state of the clamp arrangement 22.

The articles 12a-d travel towards the helical wrapping apparatus 6 via the infeed device 4. Specifically, in the position of the collation 12 shown in Figure 4, the feed conveyor 20 is used to transport the collation 12 towards the base conveyor 16 and the first and second support conveyors 18a, 18b.

Once the articles 12a-d are arranged in a collation 12 by the collating means 22, the collation 12 is stabilised by guides 50a, 50b. The guides 50a, 50b are disposed along the feed conveyor 20. Each of the guides 50a, 50b comprises a respective guide rail 50c, 50d which is supported in situ by a pair of clamps. Guides 50a, 50b, specifically the guide rails 50c, 50d thereof, guide the collation 12 articles along the feed conveyor 20 in a direction of travel 14. The guides 50a, 50b can be said to define a channel, of which a lower side is defined by the feed conveyor 20. The channel advantageously ensures that the position, and orientation, of the collation 12, and articles forming part thereof, is maintained.

At a downstream end of the guides 50a, 50b, the collation 12 is first engaged by the first and second support conveyors 18a, 18b. As previously discussed, each of the first and second support conveyors 18a, 18b engages a different, and opposing, effective face of the collation 12. The support conveyors 18a, 18b advantageously engage the collation 12 before the collation 12 leaves the feed conveyor 20. That is to say, it is advantageous that the support conveyors 18a, 18b engage the collation 12 whilst the collation 12 still engages the feed conveyor 20.

The collation 12 is then subsequently engaged by the base conveyor 16, beyond a downstream end of the feed conveyor 20. Each of the first and second support conveyors 18a, 18b and the base conveyor 16 are operated at the same speed such that respective collation engaging belts (labelled 28a, 36a, 42a in Figure 2) move at the same linear velocity. The speed control may be achieved using a servo or other suitable method or component, such as analogue drives and/or timing belts. The collation engaging belts 28a, 36a, 42a may otherwise be described as first belts 28a, 36a, 42a. The support conveyors 18a, 18b therefore effectively engage the collation 12 across both the feed conveyor 20 and base conveyor 16. This advantageously provides a supported transition of the collation 12 from the feed conveyor 20 to the base conveyor 16. This advantageously reduces the risk that the collation 12 becomes misaligned/becomes loose as the collation 12 passes from the feed conveyor 20 to the base conveyor 16. The support conveyors 18a, 18b therefore ensure an effective crossover of the feed and base conveyors 20, 16 without gaps forming between the articles which, in turn, form the collation 12.

As the collation 12 is transported towards the helical wrapping apparatus 6, one or more further wraps may be applied to the collation 12. These may be of the form of, for example, a base wrap or an upper wrap. As suggested, a base wrap may be applied to a base of the collation 12. An upper wrap may be applied to a top face of the collation 12.

In the arrangement shown in Figure 4, a base wrap may be applied by a film roll which is secured to a base film spindle 58. In Figure 4, no film rolls are shown in situ and the spindles are instead free of any such film roll. Figure 5, which will be discussed in detail later in this document, shows two such film rolls labelled 65a and 65b.

Advantageously the base wrap is applied as the base film roll is unwound. This may be achieved by, for example, frictional engagement of a free end of the film roll on either the collation 12 or an underside of the base conveyor 16. By virtue of the frictional engagement and the moving conveyors and/or collation 12, the film may be unwound from the film roll (which, again is not shown in Figure 4).

The base wrap is advantageously applied under tension. That is to say, the base wrap film is stretched as it is applied to the collation. The tension may be achieved using a magnetic resistance roller 99, which is provided between the base film spindle 58 and the collation. Applying the base wrap under tension is advantageous because, once the base wrap is trapped between the articles 12a-d and a helical wrap applied by the helical wrapping apparatus 6 (as will be described in more detail below), a laterally inward force is exerted along a length of the collation. That is to say, the base wrap generally contracts and urges the articles 12a-d more closely together. This results in a more rigid, and tightly bound, collation than would otherwise be possible without a tensioned base wrap. It will be appreciated that the base wrap may be referred to as a base film. Whilst the magnetic resistance roller 99 is used in the illustrated embodiment, the film may be tensioned by another means, such as mechanical resistance for example. All of the above is also equally applicable to an upper wrap (e.g. a further wrap applied to a top of the collation, and which generally opposes the base wrap), where incorporated. For completeness, no upper film spindle or resistance roller, associated with the aforementioned upper wrap, is shown in Figure 4.

In the Figure 4 system, the base film is applied to the underside of the base conveyor 16. When the collation 12 leaves the downstream end of the base conveyor 16, the base wrap is then in direct contact with the underside of the collation 12. As the collation 12 is transported by the base conveyor 16, the base conveyor 16 may interpose the collation 12 and the base wrap. That is to say, the base conveyor 16 may be, in effect, sandwiched between the collation 12 and the base wrap. Because the inner and outer surfaces of the base conveyor 16 move in the same direction, owing to there being two belts, the base wrap is transported along the conveyor 16 with the collation 12. In other arrangements, a base wrap may not be applied to the collation 12.

In other arrangements, an upper wrap may also, or alternatively, be applied using a similar mechanism to that described in connection with the base wrap. However, the upper wrap may be applied to an upper side, or face, of the collation 12. In embodiments (i.e. that shown in Figure 4) where there is no equivalent base conveyor 16 in contact with an upper effective face of the collation 12, an upper film may simply be applied by virtue of a free end of a film roll being unwound. However, in other embodiments a top conveyor, which generally opposes the base conveyor 16, may also be incorporated.

As the collation 12 is transported towards the helical wrapping apparatus 6, the helical wrapping apparatus 6 is operated to apply a helical film wrap to the collation 12.

Considering the specifics of the helical wrapping apparatus 6, the wrapping apparatus 6 comprises a fixed structure 60. As suggested, the fixed structure is fixed relative to a supporting structure of the overall system 2. The fixed structure 60 comprises an aperture 86 through which the wrapped collations 12 pass in use. The helical wrapping apparatus 6 further comprises a rotatable annulus 62 and a film roll mount 64. The film roll mount 64 is mounted to the rotatable annulus 62 and moves therewith. The film roll mount 64 comprises a film roll spindle 66 and a tensioner 68. The helical wrapping apparatus 6 is shown in isolation in Figure 5.

In use, and as shown in Figure 5, a film roll is disposed on the film roll spindle 66 and is positioned over the tensioner 68. The film is then applied to the collation 12 as the rotatable annulus 62 rotates. The film roll mount 64, and so film roll mounted thereto, rotate with the rotatable annulus 62. As such, the rotatable annulus 62, and film roll, rotate about an axis which generally passes though the circumferences defined by the rotatable annulus 62.

In use, the rotatable annulus 62 is driven by a wrapping motor 70, which drives a gear 72. In turn, the gear 72 is in meshing engagement with an internal meshing surface 62a of the rotatable annulus 62. Therefore, by operating the wrapping motor 70, the gear 72 is rotated and, in turn, the rotatable annulus 62 is also rotated. By virtue of the rotation of the rotatable annulus 62, and frictional engagement of a free end of the film with the collation 12, the film is unwound from the film reel and applied to the collation 12 to wrap the collation. Where a base wrap is also applied, the base wrap may also be enclosed by the helical wrap applied by the helical wrapping apparatus 6.

As shown in Figure 4, the support conveyors 18a, 18b extend through an internal bore defined by the rotatable annulus 62 (e.g. the internal surface 62a). That is to say, the support conveyors 18a, 18b extend through, and past, the meshed surface 62a of the rotatable annulus 62. The support conveyors 18a, 18b can therefore be said to extend through, or penetrate, the helical wrapping apparatus 6. This advantageously supports the collation 12 during the wrapping process (i.e. whilst the helical wrap is applied). In other embodiments, the support conveyors 18a, 18b may extend up to the rotatable annulus 62. That is to say, the support conveyors 18a, 18b may terminate at the rotatable annulus 62. In further alternative embodiments, the support conveyors 18a, 18b may terminate short of the annulus 62. That is to say, the support conveyors 18a, 18b may not extend up to the rotatable annulus 62, but may generally extend in a direction towards the rotatable annulus 62. As mentioned above, the film roll is, in use, mounted to the film roll spindle 66. As such, a longitudinal extent of the film roll (taken in the direction of travel 14) determines the longitudinal extent of the collation 12 to which the wrap will be applied. That is to say, film is unrolled from an entire height of the film roll and subsequently applied to the collation 12. The helical wrapping apparatus 6 can therefore be said to define a helical wrapping zone which is equivalent to the longitudinal extent of the film roll. The helical wrapping zone is a region in which film will be applied to the collation 12 as the collation passes through the helical wrapping apparatus. Although not illustrated in Figure 4, a longitudinal extent of the helical wrapping zone is indicated in Figure 5 by numeral 67. This is also indicated schematically in Figure 7a (by film 96).

As will be appreciated from Figure 4, each of the base conveyor 16 and the first and second support conveyors 18a, 18b extend into the helical wrapping zone. The wrap is therefore applied at least partially to each of these conveyors 16, 18a, 18b during the wrapping process. However, because the conveyors are in operation, the wrap disengages the conveyors at a downstream end of each of the conveyors such that the wrap directly engages all effective faces of the collation 12. Put another way, the film is urged along an outer surface of the conveyors until the film passes over a downstream end of the conveyors. At this point, the film then directly engages the collation (i.e. the conveyors no longer interpose the film and the collation). By being engaged with the effective faces of the collation 12 during the wrapping process, the base conveyor 16 and first and second support conveyors 18a, 18b provide a supporting, or guiding, force to maintain the alignment and arrangement of the collation 12. This provides an improved quality wrap over arrangements where no supporting conveyors are present.

Although the helical wrapping apparatus 6 in the illustrated arrangement has a single film roll mount 64, to which a single film roll is, in use, mounted, in other arrangements the helical wrapping apparatus 6 may comprise a plurality of film roll mounts. In other arrangements, the helical wrapping apparatus 6 may therefore comprise a plurality of film rolls mounted to the respective plurality of film roll mounts.

Turning to the components downstream of the helical wrapping apparatus 6, a downstream conveyor 8 is formed of two portions: a first portion 74 and a second portion 76. The first portion 74 comprises upper and lower conveyors 78, 80 respectively. The second portion 76 comprises a single conveyor.

The upper and lower conveyors 78, 80 of the first portion 74 engage the wrapped collation and transport it away from the infeed device 4. The wrapped collation may be said to be transported away from the helical wrapping zone by the upper and lower conveyors 78, 80. As shown in Figure 4, the support conveyors 18a, 18b overlap the upper and lower conveyors 78, 80 in the direction of travel 14 such that the collation is continuously supported across both sets of conveyors. That is to say, the wrapped collation is transferred from the support conveyors 18a, 18b to the upper and lower conveyors 78, 80. The collation is therefore continuously engaged by at least two conveyors from the point at which the collation is engaged by an upstream end of the support conveyors 18a, 18b to the point where the collation disengages the downstream end of the upper conveyor 78.

Disposed between the first and second portions 74, 76 of the downstream conveyor 8 is a cutting apparatus 82. In the illustrated embodiment the cutting apparatus 82 is in the form of hot wire, but it could otherwise be a blade, heated or otherwise, or other means of cutting. Other alternatives include heated elements, lasers and ultrasonic devices. A non-thermal mechanical device, such as a non-heated blade, may be used. The cutting apparatus 82 provides a cutting functionality to separate the wrapped collations of articles into separate wrapped collations. That is to say, as the collations pass through the helical wrapping apparatus 6, the film is applied but the individual wrapped collations are not separated until they pass through the cutting apparatus 82.

At the downstream end of the second section 76 of the downstream conveyor 8, the collated articles are therefore in a wrapped, and separated form. In this instance, separated is intended to mean the individual articles are still collated in a collation, but that the collations are individually wrapped. The quality of the wrap is improved due to the incorporation of the first and second support conveyors 18a, 18b. The support conveyors 18a, 18b ensure the collations, specifically the articles 12a-d forming part thereof, remain correctly aligned and grouped as desired. Any gaps between articles within the collation may cause undesirable looseness and a possible loss of pack functionality. The upper conveyor 78 serves to grip the wrapped collation and draw, or pull, the wrapped collation out of the helical wrapping zone. Once the wrapped collation passes the cutting apparatus 82, and the film is therefore separated, the separate wrapped collation can travel freely on the second portion 76 of the downstream conveyor 8. That is to say, an upper conveyor may not be required for the second portion 76, because the separate wrapped collation can be transported using only a lower conveyor.

Although not previously discussed in detail, it will be appreciated that the entire system shown in Figure 4 is supported by a rigid structure or framework, including legs labelled 84. The structure 84 may be height adjustable to facilitate the smooth, and level, flow of articles through to the helical wrapping zone of the helical wrapping apparatus 6.

Turning to Figure 5, a perspective view of the helical wrapping apparatus 6 in isolation of the rest of the wrapping system is provided.

Figure 5 illustrates the fixed structure 60 and the wrapping motor 70 attached thereto. The gear 72 is also shown meshing with an inner, toothed surface (or internal meshing surface) 62a of the rotatable annulus 62. As previously mentioned, it is by virtue of the wrapping motor 70 driving the gear 72 that the helical wrapping apparatus 6 is operated. The fixed structure 60 defines the aperture 84. It is through the aperture 84 that wrapped collations are transported after, or as, the film is applied. The first and second support conveyors 18a, 18b may project into the aperture 84. The base conveyor 16 may project into the aperture 84.

In the Figure 5 embodiment, the helical wrapping apparatus 6 comprises a pair of film roll mounts 64a, 64b. The pair of film roll mounts 64a, 64b are diametrically opposed relative to one another. That is to say, they are disposed at opposing points on a circumference of the rotatable annulus 62. In other embodiments, one, three or more rolls, and a corresponding number of roll mounts, could otherwise be used. However, the applicant has found that the use of two film rolls, and a corresponding two film roll mounts, facilitates an advantageously swift wrapping speed, or throughput, whilst avoiding the film being undesirably “dragged” through to the downstream conveyor 8 without being properly applied to the collation 12. Film rolls 65a, 65b are also shown mounted over a respective film roll spindle 66a, 66b. As best shown in connection with the upper film roll mount 64b, a free end 65c of the film roll 65d passes over the tensioner 68b. If the free end 65c was to be pulled further away from the film roll spindle 66b, to unravel the film roll 65b to a greater extent, the free end 65c could engage a collation of articles. When in this position, operation of helical wrapping apparatus 6, by virtue of rotating the rotatable annulus 62, will unravel, or unreel, the film from the film roll 65b to helically wrap the collation of articles.

Figures 6a and 6b are side and plan views of the helical wrapping system 2 respectively.

As previously described in detail, the system 2 comprises the infeed device 4, helical wrapping apparatus 6 and downstream conveyor 8. Housing 10 is also shown in-situ.

The longitudinal extent, or length in the direction of travel, of the helical wrapping zone is indicated in Figure 6a with numeral 67.

Figures 6a and 6b show, in more detail, the arrangement of the collation means 22 and sorting means 24, both of which are provided along the feed conveyor 20.

Turning to Figure 6b, the sorting means 24 comprises a sorting wheel 86 and a guide 88. The sorting wheel 86 is a star-shaped body comprising a plurality of projections which, in turn, define a plurality of recesses configured to receive an article therein. In use, the sorting wheel 86 is rotated as a single article 12a-d passes between a recess of the sorting wheel 86 and the guide 88. As the article 12a-d engages the recess of the sorting wheel 86, a bumper arm 93 abuts the article 12a-d and, in cooperation with the sorting wheel 86 and guide 88, urges it into a desired alignment. The bumper arm 93 may take the form of a metal bar with a nose 95 thereon. The bar may be, for example, 12 mm in diameter. The bumper arm 93 may be said to “square” up the bottle as it rotates whilst engaging the sorting means 86, urging the article to rotate by a desired rotational amount (which may be around 90°). The bumper arm 93 may be disposed in proximity to the sorting wheel 86, and opposite the guide 88. After passing the sorting means 24, the article 12a-d has been sorted such that the article 12a-d is aligned as desired. In other words, the sorting means 24 provides a stream of aligned articles 12a-d. The aligned articles 12a-d then engage the guides 50a, 50b as they continue to traverse the feed conveyor 20. The sorting wheel 86 may be driven, or may be passive. In the illustrated embodiment, the sorting wheel 86 is rotated by virtue of the articles 12a-d moving along the feed conveyor 20 whilst received in the recesses of the sorting wheel 86, and can therefore be described as passive.

The sorting wheel 86 is an example of an article turner. The article turner may be a bottle turner. Other examples of article, and so bottle, turners may otherwise be used. Alternatively, the article/bottle turner may be omitted if the orientation of the articles 12a-d is as desired when the articles first arrive at the feed conveyor 20. The sorting wheel 86 may be said to be an example of a rotation means.

In the illustrated embodiment the guide 88 is arcuate, and so may be referred to as a curved guide, but other arrangements may otherwise be utilised.

Figure 6c is a section view of the system 2 taken about the section line indicated 71 in Figure 6b.

Figure 6c illustrates the arrangements of the various belts which form the conveyors. For example, the belt 20a forming part of the feed conveyor 20 is indicated. The first support conveyor 18a, and base conveyor 16, is also shown. Figure 6c also shows upper and lower film applicators 73, 75 respectively. The upper and lower film applicators 73, 75 are used to dispense film for the upper and base wraps respectively. The upper and lower film applicators 73, 75 may be similar in design to the film roll mount 64 illustrated in Figure 4. That is to say, they may each comprise a film roll spindle and tensioner. It will be appreciated that a range of positions of the upper and lower film applicators 73, 75 may be utilised in alternative embodiments.

A setup process for using the system 2 will now be described using the schematic illustrations of Figures 7a-f. For the avoidance of doubt, the same reference numerals used earlier in this document will also be used for like features in the schematic illustrations. The support conveyors 18a, 18b are omitted from the following Figures to improve the clarity of the illustrations.

Briefly introducing the features shown and labelled in Figure 7a, unsorted and uncollated articles 12a-d are received on a conveyor system 87 external to the system 2 (for example, a warehouse conveyor of some variety). The conveyor system 87 may be, for example, an exit, or discharge, conveyor from a filling station (where the articles, such as bottles, contain liquids or loose stuffs). The filing station may be a carton, or bottle, filling station. An upstream boundary of the system 2 is labelled 90, and a downstream boundary is labelled 92. The articles 12a-d pass the upstream boundary 90 and then pass through the sorting means 24, collation means 22 and pass an article sensor 89. The articles 12a-d are, at this point, collated as collation 12. The collation 12 then engages base conveyor 16, to which a film is applied from a base film roll 59. When the collation reaches the helical wrapping zone, the longitudinal extent of which is indicated by numeral 67, a film is applied from film roll 65, via tensioner 68, by rotation of the rotatable annulus 62 of the helical wrapping apparatus 6. The wrapped collations then engage the upper and lower conveyors 78, 80 of the first portion 74 of the downstream conveyor 8, and are transported towards cutting apparatus 82. The wrapped collation is then separated (into an individual wrapped collation) and transported further downstream by the second portion of the downstream conveyor 8, to the downstream system boundary 92. Beyond the downstream system boundary 92 the wrapped collations may be palletised for shipping. A controller 69 is used to initiate the various process steps, and as an input device which an operator can use to program various aspects of the system 2. The controller 69 may be a touchscreen controller, and may comprise a human machine interface (HMI).

Starting at Figure 7a, uncollated and unsorted articles 12a-d are received on the conveyor system 87 up to the upstream boundary 90. A setup option is then selected on the controller 69 by an operator. The setup option may alternatively be selected to initiate the conveyor system 87 to transport the articles 12a-d to the upstream boundary 90. The articles 12a-d may be provided on the conveyor system 87 individually, in groups, or in a continuous line.

Turning to Figure 7b, the articles 12a-d are then transported towards the helical wrapping apparatus 6 by the feed conveyor 20. Typically, the feed conveyor 20 runs at a slower speed than the conveyor system 87. This is to close up, or reduce, any gaps which may have existed between the articles 12a-d when the articles 12a-d were on the conveyor system 87. The relatively slower speed of the feed conveyor 20 may also negate a reduction in length, of the articles in the direction of travel, as the articles 12a- d change orientation. That is to say, the relatively slower speed of the feed conveyor 20 may be used to offset a change of an extent of the articles, in the direction of travel, as the articles 12a-d change orientation upon passing through the sorting means 24. The sorting means 24 is also activated to align the articles 12a-d to a desired position. The alignment of the articles 12a-d occurs as the articles 12a-d are transported on the feed conveyor 20. After engagement with the sorting means 24, the articles 12a-d are aligned, or sorted, into a desired alignment or format. The conveyor system 87 continues to transport articles towards the system 2 to provide an uninterrupted supply of articles.

Figure 7c shows the leading article 12a (i.e. the first article) having passed by the clamping means 22 and having reached the article sensor 89. At the point where the leading article 12a reaches the sensor 89, a desired number of articles 12a-d have been transported beyond the collation means 22. At this point, the collation means 22 is activated so as to clamp the articles 12e-h which follow the articles 12a-d which have passed the collation means 22. As the feed conveyor 20 continues to operate, a gap is created between the articles 12a-d and the articles 12e-h (which are, in effect, suspended by the collation means 22). At this point, the articles 12a-d have been grouped into a collation 12. Figure 7d indicates the gap 94 which is created between the collation 12 and the article 12e due to the collation means 22 engaging articles 12e-h whilst the feed conveyor 20 continues to operate.

Figure 7e shows a subsequent step in which the upstream collation 12 is engaged by the downstream conveyor 8 (specifically the upper and lower conveyors 78, 80 thereof). As the present method is the setup process, in the step shown in Figure 7e the films 96, 98, from the helical wrapping apparatus film roll 65 and the and the base film roll 59, are applied to the collation 12. This occurs manually, owing to the collation 12 being the first collation to be wrapped with the films 96, 98.

Figure 7f shows a further step in which the first collation 12 has been transported along the first portion 74 of the downstream conveyor 8 to the cutting apparatus 82. The cutting apparatus 82 separates the wrapping film applied to the collation 12 such that the collation 12 is then a separate, wrapped, collation. The cutting apparatus 82 may be activated by, for example, a sensor detecting a gap between two collations. The wrapped collation 12 is then transported away from the cutting apparatus 82 via the second portion 76 of the downstream conveyor 8. Beyond this point, the wrapped collation 12 may then be transported past the downstream system boundary 92 by another system (for example). After the films 96, 98 are applied to the first collation 12 in the step shown in Figure 7e, the films 96, 98 are automatically dispensed and applied to the subsequent collations 12’, 12” as the subsequent collations 12’, 12” are transported towards, and away from, the helical wrapping apparatus 6.

From the step shown in Figure 7f, the system 2 can operate in an automated manner to continuously sort, collate, wrap and separate articles/collations. This is, of course, providing there is a continuous supply of articles upstream of the upstream system boundary 90 (i.e. a continuous supply of articles delivered to the system 2).

Figures 8a-c schematically illustrate steps in a run-down process for the system 2.

Beginning with Figure 8a, if the system 2 detects that there is no supply of articles upstream of the upstream system boundary 90, the collation means 22 is halted so as to allow the articles on the feed conveyor 20 to continue to be transported towards the helical wrapping apparatus 6. The detection may be by way of one or more sensors. The sorting means 24 will also be halted accordingly. The “halt” may otherwise be described as a deactivation, or pause. The features downstream of the helical wrapping apparatus 6 continue to operate as normal to continue to discharge wrapped, and separated, collations. The pausing of the aforementioned components may be controller by the controller 69.

If, in a subsequent step, the supply of articles to the system 2 is restarted, such that a sufficient backlog of articles is present upstream of the upstream system boundary 90, the system 2 restarts operation in its entirety. That is to say, the collation means 22, and other features, return to normal operation.

If a run-out option is selected by an operator using the controller 69, with the system 2 in a paused state owing to a lack of articles upstream of the upstream system boundary 90, a run-out mode of operation is initiated.

The system 2 continues to operate as described above, until the last collation has been completely wrapped (see Figure 8b). At this point, the films 96, 98 are manually cut, or snapped. Of note, the base film 98 may not be broken during the run-out process. That is to say, the base film 98 may remain connected, and tensioned, even when the system 2 is purged of articles and/or during article changeovers. Changes of product type, such as flavour, or identification type (label) are examples of article changes for which the base film 98 may not be cut, and may remain in situ. It is preferable to leave the base film 98 in situ as resetting the base film 98 may be somewhat complicated, and time consuming. Typically, the helical wrap 96 is broken between the aforementioned article changes, to enable the system 2 to be purged of a previous variety of article. It is therefore possible to change the articles to be wrapped by breaking, and resetting, only the helical wrap 96, whilst leaving the base wrap 98 in situ. It may be necessary to apply the helical wrap 96 to a first collation, following a system run-out, to prevent blockage of the film in the system 2 (and specifically the base conveyor 16). In short, only the helical wrap 96 need be applied to a first collation of articles (of a new run of articles), following a system purge.

As shown in Figure 8c, the run-out process is complete when all of the collations 12 have passed downstream of the downstream system boundary 92.

One or more conveyors may be driven conveyors. One or more conveyors may be microconveyors.

The roller(s) or pulley(s) of a conveyor may otherwise be referred to as a shaft.

The terms wrap and film may be used interchangeably.

Throughout this document, inner and outer surfaces correspond with surfaces which are proximate and distal, respectively, the articles.

The described and illustrated embodiments are to be considered as illustrative and not restrictive in character, it being understood that only preferred embodiments have been shown and described and that all changes and modifications that come within the scope of the inventions as defined in the claims are desired to be protected.

In relation to the claims, it is intended that when words such as "a," "an," "at least one," or "at least one portion" are used to preface a feature there is no intention to limit the claim to only one such feature unless specifically stated to the contrary in the claim. When the language "at least a portion" and/or "a portion" is used the item can include a portion and/or the entire item unless specifically stated to the contrary.

Optional and/or preferred features as set out herein may be used either individually or in combination with each other where appropriate and particularly in the combinations as set out in the accompanying claims. The optional and/or preferred features for each aspect of the invention set out herein are also applicable to any other aspects of the invention, where appropriate.