System and method for stacking a predetermined number of nestable objects

Abstract

A system and method for stacking a predetermined number of nestable objects is disclosed, including several alternative embodiments. The system is preferably designed for use with a plurality of nestable objects each having a measurable thickness. A cavity is configured for containing the nestable objects in an orientated position. The objects may be taken directly from a manufacturing process or otherwise loaded to the system at a receiving end. An ejector mechanism operates at the receiving end of the cavity to tamp, by relatively short strokes, successive objects into the cavity until a predetermined number of objects is achieved. At the point of tamping the last object into the cavity, the ejector executes a longer stroke to advance the now vertically oriented and stacked objects toward a discharge end of the cavity. A flange is functionally positioned proximate the discharge end of the cavity to create a span within the cavity having a length. In use the flange halts the advancement of an edge of the stacked arrangement of objects while the remaining edges continue forward. The result is a change in the orientation of the stacked arrangement of nestable objects upon reaching the predetermined number of objects within the cavity. The reorienting objects are simultaneously discharged from the cavity. The length of the span created by the flange and the cycled ejector strokes cooperate within the cavity to allow for the reorientation of the same number of stacked objects each cycle.

1 . A system for stacking a predetermined number of nestable objects comprising: 
 a cavity configured to permit entry and containment of nestable objects to create an orientated, stacked arrangement, wherein the cavity has a receiving end and a discharge end    a flange functionally positioned proximate the discharge end to create a span within the cavity having a length;    an ejector mechanism functionally positioned proximate the receiving end of the cavity;    wherein the flange and ejector mechanism cooperate to change the orientation of the stacked arrangement upon entry of a final nestable object to the cavity by discharging the stacked arrangement.    
   
   
       2 . The system of  claim 1  wherein the flange is stationary.  
   
   
       3 . The system of  claim 1  wherein the flange is functionally affixed to a bottom quarter of the discharge end.  
   
   
       4 . The system of  claim 1  wherein the flange and ejector cooperative to change the orientation of the nestable objects from a substantially vertical position to a substantially horizontal position.  
   
   
       5 . The system of  claim 1  wherein the flange protrudes into the cavity.  
   
   
       6 . The system of  claim 1  wherein the predetermined number of nestable objects is within the range of 2 to 50.  
   
   
       7 . The system of  claim 6  wherein the predetermined number of nestable objects is within the range of 8 to 35.  
   
   
       8 . The system of  claim 7  wherein the predetermined number of nestable objects is within the range of 20 to 25.  
   
   
       9 . The system of  claim 1  wherein the flange is adjustable.  
   
   
       10 . The system of  claim 9  wherein the flange is adjustable perpendicular to the cavity to change the height of the flange.  
   
   
       11 . The system of  claim 9  wherein the flange is adjustable in a direction parallel to a longitudinal axis of the cavity to change the length of the span.  
   
   
       12 . The system of  claim 9  further comprising an indexing mechanism for adjusting the flange position proximate the discharge end of the cavity.  
   
   
       13 . The system of  claim 12  wherein the indexing mechanism is attached to the cavity.  
   
   
       14 . The system of  claim 1  wherein the cavity can be extended in a longitudinal direction to change the length of the span.  
   
   
       15 . The system of  claim 1  wherein the cavity can be shortened in a longitudinal direction to change the length of the span.  
   
   
       16 . The system of  claim 1  further comprising a surface for receiving the discharged stacked arrangement proximate the discharge end.  
   
   
       17 . The system of  claim 16  wherein the surface for receiving is a conveyor.  
   
   
       18 . The system of  claim 1  wherein the nestable objects are selected from a group consisting of plates, bowls, trays, cups, lids, disks, food containers, covers, and the like.  
   
   
       19 . A system for packaging a predetermined number of nestable objects comprising: 
 a manufacturing source for producing a plurality of nestable objects which are designed to be packaged;    a stacking apparatus comprising a cavity, the cavity configured for receiving nestable objects from the manufacturing source and containing the nestable objects in an orientated, stacked arrangement, the cavity comprising a flange, the flange cooperating with an ejector mechanism to automatically change the orientation of the stacked arrangement when the predetermined number of nestable objects are received by the cavity;    a packaging mechanism configured for receiving and packaging the stacked arrangement of nestable objects from the stacking apparatus.    
   
   
       20 . The system of  claim 19  wherein the flange is stationary.  
   
   
       21 . The system of  claim 19  wherein the predetermined number of objects and the number of nestable objects that are packaged are consistently identical.  
   
   
       22 . The system of  claim 19  wherein the predetermined number of nestable objects is within the range of 8 to 35.  
   
   
       23 . The system of  claim 19  wherein the objects change orientation and are discharged when the nestable objects come into functional contact with the flange.  
   
   
       24 . The system of  claim 23  wherein the flange is adjustable.  
   
   
       25 . The system of  claim 24  wherein the flange is functionally affixed proximate a discharge end of the cavity.