RIBI PACK S . p . A.
"Apparatus for holding various layers of containers or bottles on pallets in stable and orderly- arrangement"
The invention relates to an apparatus for holding various layers of containers or bottles on pallets in stable and orderly arrangement.
In prior art, bottles 2 and similar containers having a neck 4, referred to hereafter as containers 2, were stacked in layers on pallets 11, and the various layers were separated by general rigid partitions 1, commonly known as layer pads, which are often reusable, each being laid on the openings 5 of the containers 2 or bottles of each layer and in turn supporting the overlying layer of containers 2 or bottles resting on their respective bases 13.
The assembly of alternate stacks of containers 2 and general separating partitions was finally topped by a heat-shrinkable plastic sheet, which secured the load to the pallet.
Nevertheless, this method has a number of drawbacks that will be readily apparent from the following description. It is further known to seal bottles 2 or food containers by a stretchable plastic polymer membrane. Specific systems are used for this purpose, which apply these membranes 8 to the openings either individually, as bottles are conveyed on a belt conveyor, or simultaneously on arrays of bottles 2 or containers pre-arranged in a plane matrix.
These steps are carried out by devices that press the membranes 8 against the bottle or container openings while vertically- stretching them until they are annularly torn off, possibly with the help of annular blades which cut the membrane 8 after stretching and bonding of the membrane 8 itself.
A first object of this invention is to provide an improved apparatus as described hereinbefore that allows to achieve an increased and improved performance as compared with prior art apparatus.
A second object is to provide sealing of bottles or containers, in addition to arrangement thereof on the pallet. In the most general form, the invention relates to an apparatus composed of a number of rigid sheet- like perforated partitions 1, preferably with circular holes 3 aligned along lines that may be equally spaced, perpendicular or intersecting at 60°, and possibly alternated with various layers of containers 2 to be "palletized", which may be either empty or full and anyhow sealed or to be sealed.
Further features will form the subject of the dependent claims. In one embodiment of the invention, allowing to achieve both the above purposes, the holes 3 of the rigid sheet-like partitions (1) are closed by membranes of stretchable plastic polymer membranes 8.
In this advanced embodiment of the invention, one apparatus performs both the functions of multiple application of diaphragms or membranes 8 to the openings of the bottles 2 or containers, and of orderly arrangement of the latter on pallets in
various superimposed layers, by using rigid partitions 1 with holes 3 closed by said stretchable plastic polymer membranes 8. Current perforated partitions 1 which hold layers of bottles 2 or containers on orderly arrangement do not seal the bottles 2 or containers.
Therefore, this invention is mainly characterized by the presence of stretchable plastic polymer diaphragms 6 which, when stretched over the holes 3 of the partitions 1, are ready to seal the openings of bottles 2 or containers .
Even in the above embodiment, in which the holes 3 of the partitions 1 are closed by stretchable membranes 8 for sealing the bottles or containers 2, several advantageous variant or construction embodiments will form the subject of the dependent claims.
Since the rigid partitions 1 have the function of carrying the sealing membranes 8, and to hold the bottles in position when they are engaged on their necks, these rigid partitions may be relatively thin and made of a non excessively rigid material. This provides the advantage of affording material savings, both in terms of material costs and in terms of environmental impact costs. Furthermore, by limiting the rigidity of partitions to what is required for their specific function, the increase of the palletized neck weight, determined by the partitions, is also reduced. However, when the rigidity of partitions is decreased to achieve weight reduction and material savings results, as an adverse effect the application of partitions on bottle necks and
simultaneous sealing of openings by the stretchable polymer membranes 8 becomes more difficult, because the intrinsic rigidity of the partitions is insufficient for uniform pressure distribution all over the partitions and thence all over the holes 3, and the corresponding membranes 8 subtended thereby. Here, the lower rigidity of partitions may cause local deformations during the step of compression against bottles or containers, during which the membrane is stretched over the openings of the bottles or containers, whereby sealing may occur improperly in certain areas, or not at all.
To obviate this drawback, the invention further provides, in combination with the above, a tool for applying the partitions onto the necks of the bottles or containers.
This tool is comprised of a device for applying the rigid sheet-like partitions (1) and the sealing membranes (8) to the openings of containers or bottles (2) by elastic stretching and rupture of the membranes, so that the latter are bonded to such openings of bottles or containers in a sealing position, and which device is composed of a rigid grid (13) formed by rigid bars (14) joined together to form a meshed surface, which meshed surface has spaces (15) between said bars (14) arranged in such a manner that the positions of all the centers of said spaces (15) simultaneously correspond to the positions of all the openings of the containers or bottles (2) on a layer of the pallet.
The grid meshes substantially have such a size and shape that the holes 2 of the partition to be applied and thence the corresponding packages or
openings of the bottles or containers are inscribed or encircled by the segments of material that delimit one mesh of the grid.
Here again, further improvements and variants of this tool will form the subject of the corresponding subclaims.
Further improvements will form the subjects of the subclaims and the features of the invention and the advantages deriving therefrom will appear more clearly from the description of a few embodiments which are shown in the accompanying drawings, in which:
Figs. 1 and 2 are top plan and cross sectional views of two sheet-like perforated partitions of a first embodiment, with the dash lines indicating the bottles or containers to be received in or joined to said partitions.
Fig. 3 is a side view of an array of stacked bottles, packaged by using the apparatus as shown in Figs. 1 and 2.
Fig. 4 is a view of an enlarged detail of the portion of a rigid sheet-like partition 1 at a bottle neck receiving hole, and which hole has a film for temporarily sealing the opening of the bottle, when the bottle neck is partially introduced in said hole.
Fig. 5 is a view like that of Fig. 4, in which the bottle has its neck fully introduced in the hole and the sealing film is stably applied to the opening of the bottle. Fig. 6 is a construction detail of the portion of the rigid sheet-like partitions with the holes closed by the sealing films.
Fig. 7 is a partial axonometric view of a partition according to a second embodiment of the invention.
Fig. 8 is a cross sectional view of an enlarged detail of a variant of the partition of Fig. 7.
Fig. 9 shows an enlarged detail of a partition according to the embodiment of Figures 7 and 8 in an intermediate step of its application to a bottle.
Fig. 10 shows the partition according to the embodiment of Figures 7 to 9 in its fully applied condition, with particular reference to a detail of this partition, including three holes engaged on the necks of three bottles, which have been sealed at the same time as the partition has been applied to the bottles.
Fig. 11 is a perspective view of a tool for applying partitions to a layer of bottles or containers on a pallet.
Figure 12 is a schematic perspective view of a grid 13 in combination with a partition 1. One row of holes 3 is shown on the partition and the dash lines show the projections of the bars that form the grid.
Referring to Figures 1 to 3, the holes 3 of these partitions 1 are designed to receive the packages 4 of the containers 2 whereas the vertical axes of the containers 2 of one layer are preferably disposed along said parallel equally spaced lines. Thus, the packages 4 of the containers 2 of one layer are received in the holes 3 of the directly overlying partition 1 to abutment, i.e. until the diameter of the holes 3 of the partition coincides with and stops the partition at the section of the neck 4 having an equal diameter.
As a result, all the packages 4 of the containers 2 or bottles are locked by coplanar homologous horizontal sections, formed by the perforated partitions and are horizontally connected thereto. The main advantage of this apparatus, still not considering the specific implementations as defined in claims 6 to 11, i.e. the holes 3 with stretchable plastic diaphragms 8, is that a greater number of containers 2 or bottles may be stacked or loaded in a volume equal to that of traditional stacks: for instance, considering standard bottles 2, five layers may be averagely stacked instead of four, and these may be better attached to the pallet 11, and be less exposed to mutual motion, whereby handling ruptures are reduced.
From a technical point of view, the arrangement of the containers 2 or bottles of each layer shall only meet one imperative requirement, i.e. that each base 12 and/or maximum diameter of each container 2 or bottle shall be able to be received between the packages 4 of the underlying layer, projecting out of the holes 3 of the partition 1 that supports them. Many arrangements may be theoretically envisaged, but only two of them are advantageously used in practice because, as a function of the hole 3 diameter / container diameter ratio, they optimize the occupation of the available space on each partition:
1) The arrangement with the vertical axes of the containers 2 or bottles perpendicularly intersecting the partitions 1 at the centers of the holes 3 that define vertices of adjacent squares, i.e. in a palletization pattern of parallel rows.
2) The arrangement with the vertical axes of the containers 2 or bottles perpendicularly intersecting the partitions 1 at the centers of the holes 3 that define vertices of adjacent equilateral triangles. In the former case, as is apparent from Figure
1, optimization is obtained by arranging the containers 2 or bottles, so that the body of each of them is tangent to four other containers or bottles, so that the tangent points are at an angle of 90° to each other, except the peripheral containers, which are only in contact with three other containers 2. In this specific case, provided that the above conditions are met, the maximum diameter of the neck 4 in the hole 3 when the bodies of the containers 2 or bottles are in contact shall not exceed 0.414 D, where D is the maximum diameter of the body of the container 2 or bottle. This value generally corresponds to the value of the neck of common glass bottles. In the second case, as is apparent from Figure
2, optimization is obtained by arranging the containers 2 or bottles with their vertical axes intersecting the partitions 1 at the vertices of equilateral triangles, i.e. along parallel equally spaced lines, intersecting at an angle of 120°, which allow each container 2 or bottle to be adjacent to, but not necessarily in contact with six other containers, whose vertical axes are disposed at the vertices of an equilateral and isogonal triangle. Contact between containers 2 only occurs when d = 0.1547 D, where d is the diameter of the neck 4 and D is the diameter of the body of the container 2 or bottle. In normal cases, when the diameter of the
opening 5 or neck 4 is larger than 0.1547 D, the distance between axes will be of (D + d) cos 30°.
Any other arrangement is possible, but with no optimization of the ratio between the number of containers 2 or bottles and the available area for each layer.
Regarding the rigidity of partitions 1, since the latter have to alternately withstand a bending moment at the periphery of the layers containing the greater number of containers 2, these partitions 1, as defined in claim 5, shall be sufficiently rigid, therefore they may be formed, for instance, by two sheets 6 interleaved with a separating layer 7 or planar core, which is able to generate a sufficient resisting moment to minimize bending at the edges of the partitions 1. These components of the partitions 1, i.e. the sheets 6 and the separating layers 7, may be advantageously either glued together or solidarized, even temporarily, during operation, to allow the use of separating layers 7 having various thicknesses depending on loads or, as will be more apparent hereafter, as defined in claims 6 to 11, to stretch an advantageously sandwiched stretchable membrane of plastic polymers such as those mentioned below, or equivalent thereto. One method of temporary solidarization of said components of the partitions 1 consists in fastening these components 6 and 7 together by means of snap fasteners, expanders, elastic buttons or clips. This invention, which is already advantageous per se, is further volumetrically implemented, as defined in claims 6 to 11, by the use of diaphragms 8, obtained from a thin membrane of a stretchable
plastic polymer, such as "polyethylenes", "polyvinylchlorides", "ethyl vinylacetates", etc., stretched and fastened parallel to the partitions 1 in such a manner as to form coverings to close the holes, as shown in Figures 4 to 6. The purpose of this improvement is simultaneous sealing of several edges of the openings 5 of the containers 2 or bottles.
This is very useful, as it preserves hygiene inside containers 2, by preventing ingress of organic and inorganic contaminants.
In fact, the containers that come out of manufacturing lines are in sterile conditions, due to their temperature, and sterility is preserved if they are sealed by the above diaphragms 8 when they are still hot, thanks to the hermetic quality of such seals. Furthermore, these sealed containers 2 need no further washing process before being filled, which improves cost-effectiveness. The method of application of the seals, each corresponding to a hole closed by a diaphragm, consists in pressing the partition 1 perpendicular thereto against the openings 13 of the containers 2 or bottles. If this vertical movement is applied with a sufficient force, it causes the diaphragm of the membrane 8 to be stretched over the edge of the opening 5 of the container 2, and possibly torn, if desired, around the edge of the opening 5 when stretching is continued to annular rupture, to leave a membrane disk or a seal adhering to the edge. If no tearing occurs and the plastic polymer in use has suitable deformation properties, then the membrane is not torn off and caps are formed having the shape of
inverted paraboloids of revolution, which simultaneously and integrally seal all the openings 5 of the containers 2.
Regarding the bond between the membrane 8 and the opening 5, the removal of the boundary air layer between the membrane and the rim of the opening 5 of the container 2 or bottle, which is caused by the pressure exerted in the above mentioned vertical movement, and is combined in most cases with the pressure generated by the different polarities of the electrostatic charges of the materials of the container 2 and the membrane 8, allows atmospheric pressure to exert its force on contact surfaces which, thanks to the friction between the two materials, generates a sufficient resisting shear force to ensure a good bond between the seal and the opening 5. Therefore, each partition 1 having holes 3 closed by diaphragms is substantially properly positioned over a layer of pre-arranged containers 1 and then pressed thereon until sealing occurs, with or without annular tearing, as defined above. Then a new layer of containers will be placed on the partition 1, whose holes 3 have been perforated, between the packages 4 coming out of the underlying layer and will be in turn covered by another partition 1, which is pressed until it is torn or stretched, and such layers will be alternated until the last layer of containers 2.
The membrane 8 forming the diaphragms to be applied to the partitions 1 may be attached to the partitions 1 either by being simply glued to one of the two outside faces of the partition 1, or by being sandwiched between one of the sheets 6 and the
separating layer 7 by gluing or spot fastener means, such as buttons, clips or even magnetized layers.
The membrane 8 that forms the diaphragms 8 may further be provided as a single sheet of the same size as the partitions 1, which may be possibly attached along the edge, by being glued either all over the surface or at spots, as generally explained in the previous paragraph or along the edges of the partitions 1, either as parallel bands, or as disks or polygons having a sufficient diameter to allow bonding to the partitions 1 for seal application.
If the holes 3 in the partitions 1 have a stretchable plastic polymer diaphragm 8 thereon, for the diaphragms 8 to be torn off and for effective seal application to occur, the diameter of the holes 3 shall be about 20/30% larger than that of the openings 5. If the membrane is not to be necessarily torn off but only stretched until the diameter of the holes 3 coincides with an equal diameter of the neck 4, i.e. to abutment of the partition 1, the diameter of the holes 3 will have to be larger and the stretchable plastic polymer will have to be more resistant to deformation without breaking.
Once the layers of containers 2 and the interleaving partitions 1, with or without diaphragms 8, have been stacked, general covering thereof by a heat shrinkable plastic sheet will be useful to finally secure and compact the load on the pallet.
The invention includes an improvement, as defined in claims 12 and 13, for properly positioning the holes 3 of the partitions 1 on the openings 5 of the containers 2, comprising at least two holes 9 for each partition 1 preferably disposed at the corners
of the partitions, which will be fitted on at least two rigid vertical rods 10 having the same or a slightly smaller diameter, which are vertically fixed or removable in any suitable manner to the pallets, as shown in Figure 3. These at least two holes 9 will help to position the centers of the openings 5 of all the containers of the same layer in exact coincidence with the centers of each hole 3 of the partitions 1.
Figures 7 to 10 show a second embodiment of the invention, in which the holes of the partitions have diaphragms 8 formed by membranes subtended by said holes.
Referring to Figures 7 to 10, the partitions 1 used to seal, stack and stabilize the bottles 2 or containers in orderly arrangement are usually used various times for cost effectiveness purposes. To this end, they have to exhibit a sufficient resistance and not be subjected to important deformations. Regarding their strength they are preferably made of three permanently attached rigid layers 101, 201, 301: two outer layers 101, 301 which isomorphically absorb the compression and pulling stresses and an inner layer 201 which acts as a spacer core. The holes 3 will obviously pass through the three layers. The application of the membrane 8 that closes the holes 3 may occur by gluing thereof either to one of the outside surfaces of the partitions 1 and preferably on the surface closer to the opening of the bottles 2 or containers to be sealed, or between one surface of the core and that of the outer layer in contact with the
core. The use of stick and peel glues will facilitate both later removal of membrane parts still sticking to the partitions 1 after use and application of new membranes. If membranes are sandwiched between the core and one of the outer layers, the bond of the stick and peel glue between the surfaces of the core and the outer layers in contact with the membrane and the membrane itself will add strength to the partition 1.
Another simple method, that does not involve the use of adhesives all over the surface, consists in stretching the sheet or band of stretchable plastic polymer between two of the layers or outside them, and only attaching it along the edges of the partition 1 either by simply gluing it, after folding it over the edges of the partition 1, or by using four rigid elastic profiles, having a narrow U section, which press the membranes against and into the partition 1 along its peripheral edges.
If the membrane is sandwiched between the layers without using adhesives, with the help of profiles 19, the partition 1 will be preferably composed of a high-strength layer, in turn composed of three layers attached together, as mentioned above, and another auxiliary layer. The elastic profiles 19 will pinch together these two layers with the membrane sandwiched therein.
Since the stacked layers have alternately different numbers of bottles 2 or containers
the apparatus will have two sets of partitions 1 having respectively different numbers and positions of holes 3.
Assuming, as is obvious, that the bottles 2 or containers of one layer occupy the free geometric spaces between the sealed packages coming out of the underlying holes 3, the position and number of the holes 3 of a partition 1 will be different from those of the directly overlying and underlying partitions 1.
For example, when using an arrangement with the centers of the holes 3 at the vertices of adjacent squares, the holes 3 in the directly overlying or underlying layer will always have an offset arrangement, at the vertices of equal adjacent squares, but in a number that will be equal to the product of the number of holes 3 of one row + or - one hole 3 by the number of holes of one column + or - one hole 3.
Thus, for example, a maximum matrix of 12 x 12 holes 3 will overlie or underlie matrices of 11 x 11 holes 3. Other arrangements other than that with the holes arranged at the vertices of adjacent squares may be considered, even though they do not have the same advantageous ratio between the number of bottles 2 or containers and the available volume on the pallet. The preferred embodiment of the apparatus has partitions 1 comprising each one high- strength layer composed of three layers and another auxiliary layer, with the stretched
membrane 108 being sandwiched therebetween and forming diaphragms 8 at the holes. The use of stick and peel glue is limited to the peripheral edges of the partitions 1 with the membrane 108 being folded around them to be pinched between said two layers by four rigid elastic profiles 19 along the four edges of the partitions 1.
Figure 11 shows a tool for applying each partition to an array of bottles or containers 2.
This tool is a device for applying the diaphragms 8 of the rigid sheet-like partitions 1 to the openings of the containers or bottles 2 to keep them sealed. The device is comprised of a rigid grid 13 formed by rigid bars 14 joined together to form a meshed surface. This surface has spaces 15 between said bars 14 in such arrangement that the positions of all the centers of these spaces 15 simultaneously correspond to the positions of all the openings of the containers or bottles 2 on a layer of the pallet.
In accordance with another feature, the partitions are provided in combination with two or more rigid rods 12 that may be fixed perpendicular to the loading surface of the pallet. These rods may be fixed by inserting them in a corresponding support hole 11 in a peripheral area of each partition 1, with the superimposed holes 11 of the various partitions in the palletized material being coincident. The rods have a length that is at least equal
to the height of all the stacked, alternate layers of containers or bottles 2 and rigid sheet-like partitions 1, i.e. of the whole palletized stack. In addition to these rods 12, the grid tool 13 has at least two bushings or rings 16 secured at its periphery in such a position that, when the bushings are fitted on the rods, the meshes of the grid are aligned with the matrix of holes 3 of the partitions. The diameter of the bushings 16 is slightly larger than that of the rods 12 that are vertically mounted on the pallet and this allows the grid tool 13 to be properly positioned during application of the partitions 1 and the diaphragms 8 to the openings of the containers or bottles 2 and said tool and the partition to be guided during application of the corresponding layer of bottles on the pallet. The bars 14 of the grid 13 delimit meshes with either circular or polygonal shapes.
The grid 13 may have at its periphery at least two handles 18 on at least two of its opposite sides, which are used to press at least said grid 13 against the partition 1, i.e. to vertically stretch the diaphragms 8 against the openings of the containers or bottles 2.
The handles 17 are replaced by suitable rigid supports 18 to allow the device to be driven by any suitable mechanized system.
The grid 13 may have meshes of such a size that the bars do not extend at the offset holes 3 of the adjacent partitions.
Otherwise, each grid may have two sets of bushings 16 to be fitted on the guide rods 12, which two sets of bushings 16 are positioned with reference to the grid pattern so that the meshes of the grid 13 are brought to coincidence with the holes of one of the two different types of partitions 1 having an offset arrangement of holes 3, as described above.
Referring to Fig. 12, one grid 13 is shown in combination with a partition 1. One row of holes 3 is only shown on the partition, for the sake of simplicity, and numeral 13' denotes the projections of the bars that form the grid 13 on the partition 1. The bars are arranged in such a manner as to coincide with the interspaces between the holes 3.
Figure 12 also schematically shows the bushings 16 to be fitted on the rods 12.
The use of the partitions 1 and the above apparatus is simple. The successive application steps are as follows: a) preparing the partition, with the following possible membrane applications: i) membrane 108 attached to the outer surface of the partition 1; ii) membrane 108 attached between two of the three layers of the partition 1; iii) membrane 108 only attached to the outer edge of the partition 1 or the
inner edge of the layers between which it is sandwiched; iv) membrane 108 pinched between two layers by profiles 19; v) membrane 108 pinched against the outer surface of the partition 1 by profiles 19; vi) membrane 108 pinched and attached between two layers by using adhesive on the inner edges of the layers as well as profiles 19; vii) membrane 108 pinched and attached against the edge of the outer surface of the partition 1 by using adhesive and profiles 19. b) Arranging the first layer of bottles 2 or containers on the pallet. c) Fitting the at least two vertical rods 12 in the basement of the pallet. d) Introducing the rods 12 in the holes 11 of the partitions 1 until the diaphragms 8 lie on the openings of the bottles 2 or containers . e) Fitting the rods 12 in the bushings or rings 16 of the rigid grid 13 until the latter lies on the previously positioned partition 1. f) Pressing the grid 13 against the partition 1 by using the handles 17, to cause the diaphragms 8 to stretch vertically and possibly be annularly torn off around the openings of the bottles 2 or containers and having the edge of the
holes 33 abut against the base of the necks of the bottles 2 or containers, g) Removing the grid 13. h) Repeating the steps d, e, f and g for each layer of bottles 2 or containers, with the type of partition 1 suitable for each layer.
It shall be incidentally reminded that the openings of bottles 2 or containers are sealed by downwardly stretching the membrane 108, against the opening. This process has the effect of removing the boundary air layer from the interface between the membrane 108 and the glass or the other material that forms the container. Thus, atmospheric pressure acts on the contact surface, whereby the shear stresses tangent to the contact surface are equal to the friction exerted by the plastic polymer against the material of the opening, i.e. are equal to the product of the coefficient of friction by the fraction of atmospheric pressure acting on the contact surface, and by the contact area.