Pack filling machine with offset paths

Abstract

A device, system, and method for loading empty and formed six-pack bottle carriers into a larger case (i.e. a multi-pack) is provided. The packaging device includes an upper portion and a lower portion. The six-pack carriers are formed by unfolding them in the upper portion. Various components are associated with the upper portion of the packaging device. The case receives a plurality of six-pack carriers therein. The larger cases is formed by unfolding them in the lower portion of the packaging device. Various components are associated with the lower portion of the packaging device. The upper portion and lower portion operate simultaneously to efficiently produce a case have empty six-pack carriers placed therein for later filling with bottles at a downstream destination. The system includes the machine, the cases, the six-pack carriers, and the bottles, operating collectively.

What is claimed: 
     
         1 . A packaging machine having offset paths comprising:
 a first path for moving empty carriers and transforming the empty bottles carriers from a folded carrier first position to an unfolded carrier second position, wherein the unfolded carrier second position is adapted to receive bottles in slots defined by the carrier after installation into larger cases; and   a second path offset from the first path for moving larger cases and transforming the cases from a folded first position to an unfolded second position, wherein the case unfolded second position is adapted to received empty unfolded bottle carriers therein.   
     
     
         2 . The packaging machine having offset paths of  claim 2 , further comprising:
 a combined pathway extending downstream from a junction of the first and second paths defined by a combining assembly.   
     
     
         3 . The packaging machine having offset paths of  claim 3 , further comprising:
 an x-axis associated with the first and second paths;   a y-axis associated with the first and second paths;   a z-axis associated with the first and second paths; and   a first carrier storage assembly defining a first portion of the first path permitting directional movement along the y-axis and remaining constant relative to the x-axis and the z-axis.   
     
     
         4 . The packaging machine having offset paths of  claim 4 , further comprising:
 a first suction assembly defining a second portion of the first path permitting directional movement along the x-axis and the y-axis and remaining constant relative to the z-axis.   
     
     
         5 . The packaging machine having offset paths of  claim 4 , further comprising:
 a second suction assembly defining a third portion of the first path permitting directional movement along the y-axis and remaining constant relative to the x-axis.   
     
     
         6 . The packaging machine having offset paths of  claim 5 , further comprising:
 first and second punching assemblies positioned in a carrier opening area defining a fourth portion of the first path, wherein the first punching assembly moves a first punching tip in a direction along the x-axis and the second punching assembly moves a second punching tip in a direction along the z-axis.   
     
     
         7 . The packaging machine having offset paths of  claim 6 , further comprising:
 a tapered dropping flange positioned beneath the second suction assembly relative to the z-axis, wherein the tapered dropping flange defines a fifth portion of the first path permitting a carrier to be dropped from the second suction assembly in a direction along the z-axis and impact the tapered dropping flange to thereby effect movement in a direction along the x-axis.   
     
     
         8 . The packaging machine having offset paths of  claim 7 , further comprising:
 a carrier conveyor assembly positioned downstream from the tapered dropping flange and defining a sixth portion of the first path, wherein the carrier conveyor assembly permits movement in a direction along the x axis and substantially precludes movement relative to the y-axis and the z-axis.   
     
     
         9 . The packaging machine having offset paths of  claim 8 , further comprising:
 a divider plate thereby dividing a conveyor belt into two sections, wherein packaging computer logic selectively assigns the carrier to move along one of the two conveyor sections.   
     
     
         10 . The packaging machine having offset paths of  claim 9 , further comprising:
 a dropping module positioned downstream from the divider plate that receives a plurality of queued and formed carriers and the dropping module permitting movement in a downward direction along the z-axis.   
     
     
         11 . The packaging machine having offset paths of  claim 10 , further comprising:
 a larger case loading module defining a first portion of the second path permitting movement of the larger cases in a direction along the y-axis;   a larger case folding module defining a second portion of the second path permitting movement of the larger cases in a direction along the x-axis, y-axis, and z-axis;   a larger case conveyor assembly defining a third portion of the second path permitting movement of the larger cases in a direction along the x-axis and substantially precluding movement relative to the y-axis and the z-axis; and   a lifting module defining a fourth portion of the second path permitting movement in a direction along the z-axis.   
     
     
         12 . The packaging machine having offset paths of  claim 10 , wherein the larger case substantially precludes movement of the larger cases relative to the x-axis. 
     
     
         13 . The packaging machine having offset paths of  claim 2 , further comprising:
 an x-axis associated with the first and second paths;   a y-axis associated with the first and second paths;   a z-axis associated with the first and second paths; and   a large case loading module defining a first portion of the second path permitting movement of the larger cases in a direction along the y-axis and substantially precluding movement of the larger cases relative to the x-axis.   
     
     
         14 . The packaging machine having offset paths of  claim 13 , further comprising:
 a large case folding module defining a second portion of the second path permitting movement of the larger cases in a direction along the x-axis, y-axis, and z-axis.   
     
     
         15 . The packaging machine having offset paths of  claim 14 , further comprising a larger case conveyor assembly defining a third portion of the second path permitting movement of the larger cases in a direction along the x-axis and substantially precluding movement relative to the y-axis and the z-axis. 
     
     
         16 . The packaging machine having offset paths of  claim 15 , further comprising a lifting module defining a fourth portion of the second path permitting movement in a direction along the z-axis. 
     
     
         17 . A packaging machine having offset first and second paths, wherein the machine is configured to load empty bottle carriers into a multi-pack case, the machine comprising:
 a first portion of the packaging machine associated with forming empty bottle carriers along the first path;   an upstream direction and a downstream direction associated with the first path, wherein empty bottle carriers move from an folded state to an unfolded and formed state;   wherein the first portion of the packaging machine includes:
 a carrier storage assembly adapted to receive folded and empty storage bottle carriers; and 
 a carrier first moving assembly downstream from the storage assembly, wherein the carrier first moving assembly and the storage assembly cooperate to move at least one folded and empty bottle carrier; 
   a second portion of the machine associated with forming the case along the second path;   wherein the second portion of the packaging machine includes:
 a case loading module adapted to house a plurality of empty folded cases, wherein each case is larger than one of the empty bottle carriers; 
 a case moving assembly positioned downstream from the case loading module adapted remove at least one empty folded case from the plurality of empty folded cases; 
 a case unfolding assembly positioned downstream from the case moving assembly; and 
   a combining assembly located at a junction of the first path for the empty bottle carriers and the second path for empty cases, wherein a plurality of formed empty bottle carriers are placed into the case at the combining assembly;   
     
     
         18 . The packaging machine of  claim 17 , wherein the first portion of the machine further comprises:
 a carrier second moving assembly downstream from the carrier first moving assembly, wherein the carrier first and second moving assemblies cooperate to transform the carrier from the folded state to a semi-unfolded state   
     
     
         19 . The packaging machine of  claim 18 , wherein the first portion of the machine further comprises:
 a first punching assembly positioned downstream from the carrier first moving assembly, wherein the punching device is configured to square the at least one carrier from the semi-unfolded state to the unfolded and formed state.