Method of Packaging Toothbrushes

1. Field of the Invention

The present invention pertains to a packaging device, and more particularly, relates to a device to handle and load toothbrushes or any other type of brush into a carton.

2. Description of the Prior Art

Typically toothbrushes are difficult objects to control mechanically due to their light weight and tendency to bounce and also roll due to their thin profile when placed or dropped into an infeed bucket in route to a cartoner.

The present invention precisely meters toothbrushes through a containment slide and pneumatic clamp arrangement into a starwheel assembly, which orients the toothbrush for precise placement within an infeed bucket designed to minimize rolling and to maximize a secure fit of the toothbrush into the infeed bucket.

The general purpose of the present invention includes a conveyor device which is fed by a precise positive control handling system where toothbrushes in vertical containment slides are released individually by a precise and controlled metering system into slots in successive starwheel assemblies. The toothbrushes are contained in the starwheel assemblies until precise alignment with an appropriately configured infeed bucket occurs. The toothbrushes are then deposited into each of the infeed buckets or into alternate infeed buckets, depending on the number of feed devices used. The infeed buckets are configured to have a shape similar to the edge of the toothbrush which readily accommodates the profile of the toothbrush without any danger of rolling about the axis of the toothbrush.

According to one embodiment of the present invention, there is provided a framework having a centrally located toothbrush conveyor having configured and shaped buckets to accommodate the profile of a toothbrush. One or more sets of conveyors provide a supply of toothbrushes to one or more containment slides where the brushes are stacked for subsequent metering by metering devices having clamping mechanisms and release mechanisms for release of a single toothbrush into a set of slots in sets of parallel starwheels. The starwheels are in close alignment with shaped infeed buckets. A carton conveyor and a brush inserter mechanism flank and parallel the centrally located toothbrush conveyor to load the brush into a carton.

One significant aspect and feature of the present invention is a toothbrush packaging device having one or more self-regulating supply conveyor.

Another significant aspect and feature of the present invention is one or more containment slide. A further significant aspect and feature of the present invention is a clamping plate used to hold one or more toothbrushes in the containment slides.

Still another significant aspect and feature of the present invention is the use of a drop bar in conjunction with a clamping plate.

Yet another significant aspect and feature of the present invention is the precise loading of a toothbrush into slots in the starwheel assemblies.

Still a further significant aspect and feature of the present invention is the use of keeper plates with starwheels.

Yet a further significant aspect and feature of the present invention is the incorporation of infeed buckets specially shaped to accommodate the shape of a toothbrush.

Still another significant aspect and feature of the present invention is a loading arm having a configured notch for accommodation of the bristle end of a toothbrush.

Having thus described the embodiments of the present invention, it is the principal object hereof to provide a toothbrush packaging device for precise loading of toothbrushes into a carton.

Other objects of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein:

FIG. 1 illustrates a side view of the toothbrush packaging device, the present invention;

FIG. 2 illustrates a top view;

FIG. 3 illustrates a detailed view of the starwheel assembly and associated components;

FIG. 4 illustrates a side view of the containment slider the metering mechanism and the starwheel assembly;

FIG. 5 illustrates a view of the containment slide along line 5--5 of FIG. 4;

FIG. 6 illustrates a top view of the containment slide and metering mechanism along line 6--6 of FIG. 4;

FIG. 7 illustrates a perspective view of an infeed bucket;

FIG. 8A-8B progressively illustrates the placement of a toothbrush from a starwheel loader assembly to an infeed bucket;

FIG. 9 illustrates the alignment of FIGS. 10A-10B, 11A-11B, 12A-12B, and 13A-13B;

FIGS. 10A-10B illustrate a top view of conveyored loading arm conveyors and associated adjacent components;

FIG. 11A-11B illustrate a side view in partial cross section of a single conveyored loading arm prior to loading of the toothbrush into a carton;

FIGS. 12A-12B illustrate a top view of an activated single conveyored loading arm during the first stage of carton loading where the toothbrush is loaded into and past the confines of the carton;

FIGS. 13A-13B illustrate a side view in partial cross section of the toothbrush being inserted into and past the carton during the first stage of carton loading by the single activated conveyored loading arm;

FIGS. 14A-14B illustrates a top view of an activated conveyored tamper positioner arm during the second stage of carton loading where the toothbrush is repositioned fully into the confines of the carton; and,

FIGS. 15A-15B illustrates a side view of an activated conveyored tamper positioner arm during the second stage of carton loading where the toothbrush is repositioned fully into the confines of the carton.

FIG. 1 illustrates a side view of a toothbrush packaging device 10, the present invention. A series of conveyors and brush handling devices are mounted on framework 12 to load a toothbrush into a package. These devices include, but are not limited to, self regulating conveyors 14 and 14' upon which toothbrushes are transported, containment slides 16 and 16' aligned between the self-regulating conveyors 14 and 14', metering mechanisms 18 and 18', starwheel loader assemblies 20 and 20', a lower toothbrush conveyor 22 having a plurality of infeed buckets 24a-24n, a carton conveyor 26, carton placer 28 located adjacent to one side of the toothbrush conveyor 22, and a carton tray 29. A brush inserter mechanism 30 and a brush backup mechanism 31, also illustrated in FIG. 2, flank the carton conveyor 26.

FIG. 2 illustrates a top view of the toothbrush packaging device 10 where all numerals correspond to those elements previously described. Toothbrushes 32 are loaded onto the self-regulating conveyors 14 and 14' and are delivered as required to the containment slides 16 and 16'. The toothbrushes 32 descend gravitationally in a downward fashion on the containment slides 16 and 16', and are released individually by the metering mechanisms 18 and 18' into the starwheel loader assemblies 20 and 20' illustrated in detail on the figures that follow. The starwheel loader assemblies 20 and 20' deposit each toothbrush in an alternating fashion onto one of the infeed buckets 24a-24n. The toothbrushes are conveyed by the infeed buckets 24a-24n on the toothbrush conveyor 22. The adjacent flanking carton conveyor 26, brush inserter mechanism 30, brush backup mechanism 31, and a funnel guide conveyor 72 are synchronized, aligned and moved at a rate similar to and in concert with the central toothbrush conveyor 22. A plurality of conveyored loading arms 34a-34n on the brush inserter mechanism 30 slidingly position toothbrushes 32 residing on the infeed buckets 24a-24n into the cartons 36 on the carton conveyor 26. Loading arms 34a-34n are described in detail in the figures that follow. The carton flaps are then closed by conventional means known in the art.

FIG. 3 illustrates a detailed view of the starwheel assembly 20 and associate components which are descried in the figures that follow, and where all numerals correspond to those element previously described.

FIG. 4 illustrate various views of the containment slide 16, the metering mechanism 18 and other associated components. All numerals correspond to those elements previously described. The self-regulating conveyor 14 delivers a plurality of toothbrushes 32 to the containment slide 16. The containment slide 16 incorporates a plurality of slide plates including slide plates 38a, 38b and 38c whose sliding surfaces 38a', 38b' and 38c' are mounted an appropriate number of degrees from the vertical. The slide plates 38a-38c are positionally secured on a slotted hole horizontally oriented mounting bar 40 suspended between slotted vertically adjustable bars 42 and 44. A plurality of containment guide rods 46, 48 and 50 having curved ends extend horizontally over and are adjustably supported by a bracket 45 at the end portion of the self-regulating conveyor 14, and then conformingly curve about the end roller radius of the self-regulating conveyor 14 align with containment guide rods 46', 48' and 50' to parallel the sliding surfaces 38a', 38b' and 38c' of the slide plates 38a-38c. A slot area 52 is formed between the sliding surfaces 38a'38c' and the parallel portion of the rod containment guide members 46', 48' and 50'. The containment guide members 46', 48' and 50' are adjustably mounted to a slotted bar 54 and another bar 56. Support bars 53, 55 and 57 extend from the bar 56 to support the rod containment guide members 46', 48' and 50'. Toothbrushes 32 align in and descend vertically aided by gravitational forces. A sensor (not illustrated), senses the level of brushes 32 in the slot area 52 to activate the self-regulating conveyor 14 to supply toothbrushes 32 as required. A plate 58 actuated by pneumatic actuators 60 and 62 and 5an interspersed coupling bar 64 holds one or more toothbrushes 32 against the slide plates 38a-38c. The pneumatic actuators 60 and 62 are activated to allow one toothbrush at a time to be released to further descend in the lower region of the slot area 52 until contacting a horizontally aligned drop bar 66. The drop bar 66 is actuated horizontally by a rod linkage assembly 68 including a rod 70, a crank arm 72, a crank arm 74, a pneumatic dampener cylinder 73, and a rod 75. A support bar 76 adjustably mounts to frame members 78 and 80 and serves as a mount for a plate 81. Rod guides 82 and 84 and pneumatic actuators 60 and 62 secure to the plate 81. Dual actuating rods 86 and 88 align in the rod guides 82 and 84 and are bussed together by a traverse bar 90. The pneumatic dampener cylinder 73 serves to lessen rod linkage over load should the drop bar impinge upon a jammed or otherwise misaligned toothbrush entering the slotted members of the starwheel, such as 20a and 20b or the like. As the drop bar 66 is retracted to the right by action of the rod and linkage assembly 68, the toothbrush 32 resting thereupon is released downwardly into slots 92a and 94a of the starwheels 20a and 20b, and is aligned with the bristles pointing in a downward position due to the geometry and shape of the drop bar 66 and the slots 92a and 94a of the starwheels 20a and 20b. Vertically and 98 having curved semicircular surfaces 96a and 98a secure to the framework by slotted brackets 97 and 99 and closely align adjacent to the starwheels 20a and 20b to cause the toothbrushes 32 to remain in the slots 92a-92n and 94a-94n as the slots descend below the horizontal position. Starwheels 20a and 20n are rotationally driven by a chain 100, and are synchronized and aligned with the configured shape infeed buckets 24a-24n on the toothbrush conveyor 22 so that as the slots 92a-94a through 92n-94n exit the confines of the keeper plates 96 and 98, the toothbrushes 32 are simultaneously deposited in the aligned infeed buckets 24a-24n. Starwheels 20a and 20b also include corresponding cutouts 93a-93n and 95a-95n interspersed with corresponding slots 92a-92n and 94a-94n, respectively. These cutouts 93a-93n and 95a-95n provide clearance with a toothbrush in one of the infeed buckets 24a-24n should that infeed have a toothbrush residing therein.

FIG. 5 illustrates a view of the containment slide 16 along line 5--5 of FIG. 4 where all numerals correspond to those elements previously described. Illustrates in particular are the slide plates 38a-38c adjustably secured in a plurality of slotted holes in the mounting bar 40. A guide assembly 102 having a vertical guide surface 104 adjustably mounts to the mounting bar 40 via a bracket 105 to maintain alignment of the toothbrushes 32 within the slot area 52. The guide assembly 102 is also shown in dashed lines in FIG. 4. Sensors are illustrated in this figure and mount appropriately in alignment with the slot area 52 illustrated in FIG. 4 to detect the status of toothbrushes 32 aligned in the slot area 52. An upper level sensor transmitter 113 and sensor receiver 115 sense the presence or absence of toothbrushes in the mid-region of the slot area 52, and a lower level sensor transmitter 117 and sensor receiver 119 sense the pressure or absence of toothbrushes 32 in the lower region of the slot area 52. The conveyor 14 of FIG. 4 is appropriately actuated to replenish the supply of toothbrushes 32 in the slot area 52 as a result of the sensing at the mid and lower regions of the slot area 52.

FIG. 6 illustrates a top view of the containment slide 16 and the metering mechanism 18 along view line 6--6 of FIG. 4 where all numerals correspond to those elements previously described. Illustrated in particular is a toothbrush 32 being held against the slide plates 38a-38c by the actuated plate 58. The plate 58 includes recesses 58a and 58b being spaced about the rod containment guides 48 and 50, respectively. Also illustrated are the pneumatic actuators 60 and 62 and rod guides 82 and 84 on plate 81.

FIG. 7 illustrates a perspective view of one of the infeed buckets 24a-24n. The buckets 24a-24n include a body 106 having a configured shape which conforms to the geometrical shape of a toothbrush 32 having bristles 108 and a handle 110. A recessed planar surface 109 provides support for the bristle 108 sides as illustrated. A groove or channel 111 provides support for an edge of the toothbrush handle 110. Rectangular solid like shaped extensions 112,114 and 116 extend upwardly from the body 106 and have starwheel clearance spaces 118 and 120 therebetween and also include angled and beveled surfaces 112a, 114a and 116a intersecting the groove or channel 111 to assist in alignment and placement of the brushes 32 from the starwheel loader assembly 20 as illustrated in FIG. 8. Rectangular solid like extensions 122, 124 and 126 extend upwardly from the body 106 and include starwheel clearance spaces 128 and 130 therebetween.

FIG. 8A and 8B progressively illustrate placement of a toothbrush 32 from a second starwheel loader assembly 20 to an infeed bucket 24a where all numerals correspond to those elements previously described. The illustrated second starwheel assembly 20 and the first starwheel 20' operate in a similar fashion and manner, and have like and corresponding reference numerals for purposes of clarity and brevity. The starwheels 20a and 20b are rotated as indicated by arrows 125 and 127 and align a toothbrush 32 in the slots 92a and 94a with the infeed bucket 24a. During rotation of the starwheels 20a-20b, the slots 92a and 94a position the toothbrush 32 as an ever increasing radius track until reaching a point beyond and past the influence of the semicircular surfaces 96a and 98a of the keeper plates 96 and 98, respectively, and the toothbrush 32 is allowed to be released from the starwheel slots 92a and 94a. During this release gravitational forces cause the toothbrush 32 to descend to a position where the handle 110 evenly and slidingly engages the angled surfaces 112a-116a of the upright extensions 112-116. The toothbrush 32 then continues its downward sliding movement so that the lower edge of the handle 110 engages the groove 111 and so that the lower bristles 108 engage and rest upon the planar surface 109 of the infeed bucket 24a the final position of which is also illustrated at infeed bucket 24b of FIG. 8B for purposes of illustration. This final engaged position of a toothbrush 32 is also illustrated in the infeed bucket 24c down line of infeed buckets 24C, and 24b.

In FIG. 8A it is also noted that a toothbrush 32 has been previously loaded into the infeed bucket 24b by the upline starwheel assembly 20'. The cutouts 93a and 95a provide clearance between the previously loaded toothbrush 32 in the infeed bucket 24b. Clearance between the starwheel members 20a-20b is provided by the clearance spaces 118, 120, 128 and 130 as previously described in FIG. 7.

FIG. 9 illustrates the alignment of FIGS. 10A-10B, 11A-11B, 12A-12B, 13A-13B, 14A-14B and 15A-15B.

FIGS. 10A-10B illustrate a top view of a single conveyored loading arm 34a of the toothbrush inserter mechanism 30 of FIG. 1 where all numerals correspond to those elements previously described. Included are a conveyored toothbrush load gate 140 having toothbrush loading arm 34a a conveyored infeed bucket 24a, a conveyored funnel guide 142, a conveyored carton flight 144, and a conveyored toothbrush positioner gate 146 a plurality of tamper arms 174. Additional actuation, guidance and structure members for operation of the conveyored loading arm 34a are illustrated in the figures that follow, but are not included in the top views for the purpose of brevity and clarity.

FIGS. 11A-11B illustrate a slide view in partial cross section of a single conveyored loading arm 34a of the brush inserter mechanism 30 where all numerals correspond to those elements previously described. A plurality of the conveyored loading arms 34a and associated components align about the load gate conveyor 150 to sequentially load a plurality of toothbrushes 32 into a plurality of cartons 36 on the carton conveyor 26. The conveyored toothbrush load gate 140 includes a series of geometrically configured horizontally positionable loading arms such as arm 34a which travel about a conveyored load gate conveyor 150. The loading arm 34a pivotally secures to a pair of bearinged slides 152 and 153 via a connecting pivot block 154. The bearinged slides 152 and 153 and associated components traverse horizontally along supported rods 155 and 157. An actuating cylinder 156 and channel 158 direct a cam 160 connected between the bearinged slides 152 and 153 to cause the loading arm 34a, the pivot block 152 and the bearinged slides 152 and 153 to slide along the supported rods 155 and 157 and to either be active or inactive in the loading process. Other actuator cams or devices known in the art further activate the loader arms 34a further inwardly to horizontally position the toothbrush 32 as illustrated later in detail. The sliding loader arm 34a is illustrated in the inactive mode. Loading arm 34a includes two horizontal arm portions 162 and 164 with an angled arm portion 166 between the horizontal arm members 162 and 164. A notched end 168 is included at the end of the horizontal arm portion 164 to accommodate the bristle end of the toothbrush 32. The notched end 168 of the loading arm 34a aligns in a guide structure 170.

The toothbrush conveyor 22 aligns with the load gate conveyor 150. A toothbrush 32 is illustrated resting in the infeed bucket 24a in readiness for loading into the carton 36 on the aligned carton conveyor 26. A funnel guide conveyor 172 having a plurality of conveyored funnel guides 142 aligns between the toothbrush conveyor 22 and the carton conveyor 26.

A conveyored toothbrush positioner gate 146 aligns with the carton conveyor 26 and works much in the same manner as the mechanism of the conveyored toothbrush load gate 140. The conveyored toothbrush positioner arm 146 includes a plurality of conveyored horizontally positionable tamper arms such as tamper arm 174 which travels about a toothbrush positioner conveyor 176. The tamper arm 174 secures between a pair of bearinged slides 178 and 180 and slidingly engage a guide structure 175. The bearing slides 178 and 180 and associated components traverse horizontally along support rods 182 and 184. An actuating cylinder 186 direct a cam 188 connected between the bearinged slides 178 and 180 to cause the tamper arm 174 and the bearinged slides 178 and 180 to slide along the support rods 182 and 184 and to be active or inactive in the loading process. Other actuator cams or devices known in the art further activate the tamper arms 174 horizontally to position a toothbrush as later described in detail.

FIGS. 12A-12B illustrates a top view and FIGS. 13A-13B illustrates a side view in partial cross section of an activated single conveyored loading arm 34a of the brush inserter mechanism 30 during the first stage of carton loading where all numerals correspond to those elements previously described. Certain members illustrated in previous figures have not been illustrated for purpose of brevity and clarity. During the first stage of carton loading, the load gate conveyor 150 diverts or otherwise guides the end of the loading arm 34a having the conforming notched end 168 to align the conforming notch with the geometry of the toothbrush 32. The notched end 168 contacts the upper plastic edge of the toothbrush 32 and also contacts the upper and leading bristles to provide intimate brush to load arm contact, thus precluding brush misalignment as it travels horizontally across the infeed bucket 24a. After brush contact has been made, notched end 168 drops down onto the head of the brush, thus assuring that the brush 32 cannot roll over on its back or otherwise be misaligned after entering the cartons. A view of the notched end 168 prior to toothbrush engagement is included in FIG. 11B. The loading arm 34a is actuated fully inwardly as illustrated to move the toothbrush 32 from the notch 111, along and through the conveyored funnel guide 142 and into and partially beyond the confines of the carton 36 held in a carton flight such as the conveyored carton flight 144 on the carton conveyor 26.

FIGS. 14A-14B illustrates a top view and FIGS. 15A-15B illustrates a side view in partial cross section of the toothbrush 32 positioned from the position illustrated in FIGS. 12A-12B and 13A-13B and inserted fully into the carton 36 during the second stage of carton loading where all numerals correspond to those elements previously described. Prior to being positioned fully into the carton 36, the handle 110 of the toothbrush 32 is held, a toothbrush alignment flap in carton 36 is positioned and the toothbrush tamper arm 174 is activated to return the toothbrush 32 fully to the confines of the carton 36. The carton flaps are then closed by devices known to the art.

10 toothbrush packaging device

12 framework

14-14' self-regulating conveyor

16-16' containment slide

18-18' metering mechanism

20-20' starwheel loader assembly

20a starwheel

20b starwheel

22 toothbrush conveyor

24a-n infeed buckets

26 carton conveyor

28 carton placer

29 carton tray

30 brush inserter mechanism

31 brush backup mechanism

32 toothbrushes

34a-n conveyored toothbrush loading arms

36 carton

38a-c slide plates

38a'-c' sliding surfaces

40 mounting bar

42 adjustable bar

44 adjustable bar

45 bracket

46 rod containment guide

46' rod containment guide

48 rod containment guide

48' rod containment guide

50 rod containment guide

50' rod containment guide

52 slot area

53 support bar

54 slotted bar

55 support bar

56 slotted bar

57 support bar

58 plate

58a-b recesses

60 pneumatic actuator

62 pneumatic actuator

64 coupling bar

66 drop bar

68 rod linkage assembly

70 rod

72 crank arm

73 pneumatic dampener cylinder

74 crank arm

75 rod

76 adjacent bar

78 frame member

80 frame member

81 plate

82 rod guide

84 rod guide

86 actuating rod

88 actuating rod

90 bar

92a-n slot

93a-n cutouts

94a-n slot

95a-n cutouts

96 keeper plate

96a semicircular surface

97 slotted bracket

98 keeper plate

98a semicircular surface

99 slotted bracket

100 chain

102 guide assembly

104 vertical guide surface

105 bracket

106 body

108 bristle

109 planar surface

110 handle

111 groove/channel

112 extension

112a beveled surface

113 upper level sensor transmitter

114 extension

114a beveled surface

115 upper level sensor receiver

116 extension

116a beveled surface

117 lower level sensor transmitter

118 clearance spaces

119 lower level sensor receiver

120 clearance spaces

122 rectangular extension

124 rectangular extension

125 arrow

126 rectangular extension

127 arrow

128 clearance space

130 clearance space

140 conveyored toothbrush load gate

142 conveyored funnel guide

144 conveyored carton flight

146 conveyored toothbrush positioner gate

150 load gate conveyor

152 bearinged slide

153 bearinged slide

154 pivot block

155 supported rod

156 actuating cylinder

157 supported rod

158 channel

160 cam

162 horizontal arm portion

164 horizontal arm portion

166 angled arm portion

168 notched end

170 guide structure

172 funnel guide conveyor

174 tamper arm

175 guide structure

176 toothbrush positioner conveyor

178 bearinged slide

180 bearinged slide

182 support rod

184 support rod

186 actuating cylinder

188 cam

190 cam

Various modifications can be made to the present invention without departing from the apparent scope hereof.