AU2003204132A1 - Arrangement for making textured multi film solid cleanser holders - Google Patents

Description

-1-

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant/s: Johnson Johnson Limited Actual Inventor/s: Kudalkar Vijay Balkrishna and Abhyankar Prashant Narayan and Salaskar Rajesh Bhaskar and Vidwans Jayprakash Shankar Address for Service: Baldwin Shelston Waters MARGARET STREET SYDNEY NSW 2000 CCN: 3710000352 Invention Title: ARRANGEMENT FOR MAKING TEXTURED MULTI FILM SOLID CLEANSER HOLDERS The following statement is a full description of this invention, including the best method of performing it known to me/us:- File: 38851AUP00 500156887_1.DOC/5844 -2- FIELD OF INVENTION This invention-relates to an arrangement for makinS textured multi film solid cleanser holders.

PRIOR ART US Patent application No 09/503262 filed on 13th Juie 2001 relaes to textured fimi solid cleanser holders and methiods for the imaufacture and use thereof. Atextured film solid cleaner holder comprises a solid cleanser surroundcd by at least one textured film having texture variations including at least one aperture.

OBJECTS OF INVENTION An object of *the inivention is to provide ani arrangement for nwking textured multi film solid cleanscr holdcrs.

Another object of the invention is to provide on arrangement for making filled textured multi flm~ solid cleanser holders.

-3- *DESCRIPTION OF INVENTION According to the invention there is provided an arrangement for: making textured multi fim solid cleanser holders comprising a solid cleanser feed conveyor horizontaly rotatably mounted on a. first framm work and provided withi-a plurality of spaced solid cleanser holding pockets along the length thereof, a film feeding uiut comprising atlesat one pair of film unwind top rolls and at least one pair of film unwind bottom rolls rotaiably mounted on a stand at the feed end of 0h= feed conveyor, a pair of film lamination units each mounted at, the top and bottom of the first framework, a solid cleanser holder forming unit comprising a pair of horizontally contrarotatable conveyors disosed spaced one below thie other anid mnounted on a second frmeowork which is located close to the discharge end of the feed conveyor, a solid cleanser holder sealing unit, a solid. cleanser holder cutting uni a film scoring unit and a horizontally rotatable wasge film carrying conveyor mounted on the second frire work in tandem with the solid cleanser holder forng unit and a Plurality Of film tensioning rollers and a pluralit of film pulling units provided in the path of the textured film and an interitnt -4differential drive unit connected to the feed conveyor, contra-rotatable conveyors, film scoring unit waste fhnm cazryig conveyor and film pulling units.

The term textured film end texture variations as used in the specification have the samne mewenn as given in the US Patet Application No 09/503262.

The solid clemiser referred to in the specification may be a soap or detergent cake, or bar.

The following is a detaied desciption of the invention with reference to the accompanying drawings, in which: Fig I is elevation of an aamigement for maoking textured multi fim Solid cleanser holders according to a embodiment of the invention; Fig 2 is enlarged elevation of a ih lamination unit of the anmgement of Fig 1; Fig 3 is isometric view of a movable laminator plate or stationary laminator plate of the film laination uni't of Fig 2;, Fig 4 is enlarged elevation of the solid cleanser holder scaling unit of the aran~ement of Fig 1, Fig 5 is front view of the mnovablc die plae or stationay die plae of the solid. cleanser holder scaling tunit of Fig 4; Fig 6 is enlnred elevation of the solid cleanser holder cutting unit of the an-gcment of Fig 1; T Fig 7 is front. view of the movab1b punch plate of the solid cleanser holder cuttiug unit of Fig 6; -6- Fig8 isan enlarged vicat X inig 6; Figs 9 and 10 are elevation and side, view of the film scoring unit of the arrangcmczn of Fig 1, Figs IIad12 we eletiondSde viwof a flm pulingunit Of the rang~ienof Fig 1; Fig 13 is s chematic view of the intermittent differential drive unit of the arrangement of FiS 1; Fig 14 is schematic view of the pneumatic cylinders of the film laniination units, solid cleanser holder sealing urit end solid cleaser holder *Cuung Unit of the arragement. of Fig I Iconnected to a pneumatic supply thxpugh 5-poit 2-position solenoid cperatcd dirction coznfrol valves; and F igs 15,. 16, 17, 1S and 19 show the van'ous positions of the Gen-eva drive in a cycle of oprration of the arragement of Fig I-and -7- Fig 20 is crosssection of a multililm solid cleanser holder made by dhe arrungement of Fig 1.

As ilustratcd in Figs 1 to 20, of Lhe accomponying drawings, the armngement 1 comprises a solid clewnse feed conveyor 2 horizontally rotatably mounted on a first frtue work 3 and provided with a plurality of spaced solid cleanser holding pockets dlong the length thereof (Fig E~ach of the solid, cleanser holding pockets comprises a pair of spaced uprigh members 4 fitted across the lengt of the feed conveyor. A pair of fflm unwind top rolls 5,5 and a pair of film unwind bottom rolls 6,6 are rotatably mounted on a stad 7 at the feed end 3 of the feed conveyor. 9,9 represent ffie shafts of the film.-unwind top rolls. 10, 10 represent the shafts of the film unwind bottom rolls. I la end I lb are a pair of film humination uits, each mounted at the top and bottom of the first famework 3.Each of the film lanuation uit3 compriszs a first pneumatic cylinder 12rmounted on the top horizontal member 13 of a first supporting structure 14 and hwang a first piston 15 reciprocating therein (Figs 2 and The first piston rod 16 protrudes down from the first cylinder through the top horizonta member of the first SUPPotng structure. Air inlets cum outlets at the cylinder side and piston side of the first cylinder are imarked 17 anid 18. respectively. The cylinder side and piston side of the first pnumatic cylinder are connected to a preumatic supply 19 through a- 5 port 2-position solenoid operated direction control valve 20 and a control valve 21 (Fig 14). The 5 ports of the valve 20 are marked a, b, c, d, and e. The solenoid of the valve 20 is marked 22, 2 3 is amovablemlaor platefited toa frst guideplte4 which in turn is flind to the protrudig end of the first piston rod (Figs I and The first guide plate is up and down slidably engaged over Suide rods 25 of the first supporting structure through busbas 26 fatted to the guide plate. 27 is a stationary lamuinator plate fitted at the base 22 of the first supporting structure agincd with the movable lamnmator plte. Both the movable laminator plate and stationary lmninator plate are provided with a pair of spuced laminating ridges 2-9 across the length thiereof (Fig lBoth the movable laniinator platc and stationary h-ininator plate are also provided wiflh electric heating elements comprisig conductors 30 running thcrethiough and connected to an AC -9supply- (not shown) th-rough thermostat (not shown) and temperature controller (not shown). 31 is a solid cleanser holder forning unit comprising a pair of horizontaly contrarotatable conveyors 32 and 33 disposed spaced one below the other and mounted on an upri&h structure 34 of a second ramework 35' which is loczded close to the discharge end 36 of the feed conveyor (Fig The bottom mid top rollers at t he feed end 37a and discharge end 37b of the contraotatable conveyors are marked 38a and 38b and 38c and 39d respectively. The shaft of die rollers 38a, 33b, 38& and 38d ate marked 39a, 39b, 39c and 39d respectively. The first framework 3 is provided with a flat protrusion 40 at the dischargc end 36 of the feed conveyor extending to the feed end 37a of the contrarotatable conveyors. 41 is a. solid cleanser holder sealing, unit mounted on the second fr-amework and compiming ,a second pneumatic cylinder 42 mounted on the top hofizontal member 43 of a second suppoiting structure 44 and having a second piston 45 reciprocating therei (Fias 1 and The second piston rod 46 protrudes down from the second cylinder through the top horizontal member of the second sllppoitl~g structure. Air inlets cunm outlets at the cylindijr side and piston side of the second cylinder side axe marked 47 and 48 respectively. The cylinder side and piston side of the second cylinder ame connected to the pneumatic supply through a 5 port 2-position solenoid operated direction control 49 and control valve 21 (Fig 14). The. 5 ports of the valve 49 are'marked a, b, c, d, and The solenoid of the valve 49 is marked 50. 51 is a movable die plate fitted to a second guide plate 52 which in turn is fItted to the protruding end of the second piston rod and up and down movably engaged over guide rods 53 of the second supporting structure through bushes 54 fitted to the guide plate 52. 55 is a stationary die plate fitted at the base 56 of the second supporting structure aligned with the movable, die plate. The movable die plate 51 and stationary die plate 55 are formed with die stockets 57 corresponding. to the size of the solid cleanser holders and provided withi electric heating elements comprising conductors 58 around the sockets end conncted to the AC supply through thermostat (not shown) and temiperature controller (not shown). 59 is a solid cleanser holder cutting unit maoun-ted on the sccond framework 35 and comprising a third pneumatic cylinder 60 mounted on the top horizontal member 61 of a -11third supporting structure 62 and having a third piston 63 reciprocefing.

therein (Figs 1 and The third piston rod 64 protrudes down from the third cylinder through the top horizontal member of the third supporting structure. Air inlets cumn outlets at the cylinder side and piston side are masrked 65 end 66 respectively. The cylinder side and piston side of the third cylinder are. connected to the pneumnatic supply through 5 port 2-position solenoid operated direction control valve 67 and control valve 21 (Fig .14).

Thec fIve ports of the valve 67 are numbered a, b, c, d and e. Solenoid of the valve 67 is marked 68. 69 is u movable punch plate fitted to a third &udo plate 70 which in turn is fitted to the protruding end of the third piston rod and up and down slidably* enguged over guide rods 71 of the third supporting structure through bushes 72 fitted tereto. The movable: punch plate is provided with a pair of holes 73 defining neck portions 74 (Fig 75, 75 are a pair of sciew members each being movably dispored in each of the holes with the heads of the screw members adapted to abut against the shoulders 77 of the neck portions (Fig 78 is a retainer flange providad at the front side of the punch plate in thread engagement wih the edges of the screw -12members. The, ftlm -retainer flunge is held stressed by tension springs 79 disposed over. the screw members, and located between the punch plate and the film. retainer flange. 80 is a stationary die plate fitted at the base 81 of the third -supporting structure alied with the mo~vable punch plate. The movable punch plate and stationary die plate ar e formed with die cavities 82 *which are larger than the die sockets in the movable die plate. and stationary die plate of the solid cleanser holder scaling unit and are corresponding to the profiles of tli edgzs or fil-ls of the solid cleanser holdcr The bottom of the die cavity 82 in the stationary die plate 80 is open. 83 isan opening in the base of the third supporting structur coirespording to the open bottom die cavity in the stationary die plate 80. 8isa fimscoring unit mounted on the second f-rmework 35 and comprising mi anvil roller 85 whose shaft 86 is rotatably supported in a pair of fims vorticul oblong slots 87 provided in a pair of spaced first vortical side plates 88 of a fourth supporting structure 89 (Figs 1, 9 and 10). The bcarings 90 of the imvil roller shaft are located at the b6oltomn of the first vertical oblong slots. Therefore, the anvil roller rcmains in position. 90a is a dfiver gcor filled onthe diaft 86 at its one end. 91 is a -13rotary disc cutter disposed across and close to the anvil roller and having its shaftc 92 fitted with bearings 93 mounted in the first vertical oblong slots in the first vertical plates. 93ais adriven gear fitted onshaft 92atts one end.

Gears 90a md 93a arcinnmesh with each other (Fig The bearings 93 ame stressed by tunsion sprhng 94 in abutmnent with. flst setting screws secured through the top h6zizontal member 96 of the. fourth supporting structure in* thread engagement th.'erewith. The first. setting screws are provided with first lock ijuts 97. The clearance between the rotary disc cutter and the anvil roller is adjusted by moving the rotary cutter.down by turning and moving down the setting screws aga'ist the tension springs and stressing or compressing the tension springs. The setting screws are locked in position with the lock nuts against the horizonta nember of OWe fourth Supporting strncttire. 9~3 is a horizontilly rotatable waste film cWnymg conveyor mounted between a pair of upright members 99 of the second framework Only one of' the upright racnbcrs is seen in Fi~g I as the other is behind the one shown in Fig 1. The solid cleanscr holder sealing unit, solid cleanser holder cutting unit im scoring unit and fim carrying conveyor are in -14tanidem with the solid cleanser holder forming unit. 100 represents a plurality of film tensioning rollers. 100a, 100b, 100c and 100 d represent a plurality of film pulling units, (Fig Film pulling unit 100a is mounted on the upright structiu 34. Film pulling units 100b and 100c and 100d are mounted directly on the second framework 35. Each of the film pulling units l00s, 100b; 1O0c'and 100d comprises a pair of horizontally contrarotatable rollers 1 mnd 102 disposed one below the other in contact (Figs I11 and 12). The shaft 103 of the bottom roller 101 is fitted with beafings 104 at the ends thereof which are located in a pair of second vertical oblong slots 105 provided in a pair of spaced second vertical side plates 106 of a fifth supporting structure 107. 1The bcarings 104 of the shaft 103 are located at the bottom of the oblong slots 105. Therefore, the bottom roller 101 remains in *position. 104a is a driver pea fitted at one end of the shaft 103. Theshf 108 of the tbp roller 102 is fitted with beuig 109 at the ends thereof which re located in the second vcitical oblong slots 105. 109a is a driven gza fitted at one end of the shaft 108. Gears 104a and 109a arc in mesh with each other (Figs 11I and 110, 110 are puir of sacond setting screws whose edges are in contact with the beazings 109. The second setting screws 110 are *secured through the top horizontal, member I1I1 of the fifth suppoiting structure, i thread engagement therewith. The second setting screws are provided with second lock nuts 112. The ckzanmce between the top roller mnd bottom, roller is adjustable by huming and moving down the second setting screws against the tension springs and stressing or compressing the tension springs. The second setting screws are locked in position with the loAkuut againSt the horizontal member of the filh supporting structure. 113 is a. geared mnotor whose shaft is marked 114. 115 is a six station Geneva drive compressin a Geneva wheel 116 and a Geneva driver 117. Geneva wheel shaft is marked 118. Six slots of the Genva wheel are marked I119a, 119W, 119c, 1194, I119c and .119f. Geneva diver shiaft is marked 120. 121 is pinion of the Geneva diver. 122 and 123 are sprockets mounted on the motor shaft and Geneva driver shaft respectively end interconnected by chlln 124. The teeth ratio of sprockts 122 wid 123 is 2:3. 125 is a sprocket mounted on the Geneva wheel shaft. 126, 127, 128, 129 and 130 are sprockets mounted on the shaft 39c of roller 38c of conveyor 33. .Sprockets -16- .125 and 128 are intterconnected by chain 132. 133 is a drivez roller shaft of the feed conveyor 2. 134 is a sprocket mounted on the drive roller shaft 133.

Sprockets 126 and 134 are interconnected by chairt 135. 136 is a sprocket mounted on the driver shaft 137 of the film pulling unit 100&. Sprockets 129 wd 136 arc inteconnected by chain 138. 139 is a sprocket mounted on the driver shell 140 of the film pullingtunit 100b. Sprockets 130 and 139 are interconnected by chain 141. 142 ad 143 are sprockets mounted, on the driver shaft 144 of the filmi pulling unit 100c. Sprockets 127 and 143 art interconnected by chain 145. 146, 147 and 148 are sprockets mounted on the driver shaft 149 of the film pulling unit 100d., Sprockets 142 aid 146 are interconnected by chain 149. 150 is a sprocket m .ounted, on the driver shlf 151 of the waste film carrying conveyor 94. Spr ockets 147 and 150 are interconnected by chain, 152. 153 is a sprocket inouraed on. the driver shaft 154 of the ffim scoring unit 84. Sprockts 148 and 153 are interconnected by chain 155. The teeth ratio of sprocket 125 to each of sprockets 126 to 130, 134, ad to each of sprockets 136, 139, 142, 143, 146, 147, 148, 150 and 153 is 1: 1. Teeth rufioof gears 90a and 104a is alo 1: 1. The operation of the -17arrngmeLt of the invention is in a cyclic mniamir as described below during which valve 21 remains open.

At the beginnin of a half cycle of operation of the arrangemevnt, pinion 121 of the Geneva driver 117 is positioned at the mouth of slot 1 19a the Geneva wheel 116 (Fig 15). During rotatic of the Geneva driver in thre anticlockwise direction pinion 121 travels away from slot 119a as shown in Figs 16 and 17 and no drive is transmitted to the Geneva wheel 116 and the solid cleanser feed conveyor 2. solid cleanser holder formning unit 31.

comprising contrirotatable conveyors 32 and 33, film pulling its 100a, 100b, 100ck and 100d, filmi scoring unit 84 and waste film carrying conveyor 9A re-main stationary.. Ports a and e and ports b and d of valves 20 of the film lImnwtion units Ila and lI b re connected. Air flows into the piston side and air flows out into the atmosphecre from the cylinder side of the cylinders 12. Pistons 15 of the cylinders 12 alongwitli the movable laminator plates 23 miove down towards the stationary laminator plates 27 of the film, lamination unis. Both the movable laminator platzs 23 and stationary laminator plates -18- -27 are being, heated by the electric conductors 30 nuining trethrough.

Both the flmns .156, 15,6 from top unrwind. rolls 5 positioned in the top lamination unit I is are hot pressed together mid laminsad into a singl top flm -along the laraination ridge.s 29 of the movable laminator plate 23 and staftonary laminator plate 27 of the top lamination un it I is. Sinilarly both the films 156, 156 from the bottomi unwind rolls 6 positioned. in the bottom lamination. unit Ilb are hot pressed together and laminatd into single bottom film along the lamination ridges 29 of the movable lamfinator plate 23 miad stationary laminatoi plate 27 of the bottom lamination unit Ilb. The laminaed top and bottom films emergng from the lamination wlits Ore mnarked 157.' The filns on the unwind rolls may be Of tAW sUa Or diffirent materials, textures or colours as required. Ports b and d and ports a and* c of valve 49 of the solid cleanser sealing unit 41 Ere connected- Air flows into the piston side and sir flows out into the utn'osPhere from the cylinder side of the cylinde 42 of thec solid clexiser sealing unit 41. The piston 45 of cylinder 42 along with the movable die plate 51 moves down towards the stationary die plate 55, Both the die sockets 57 in the movable die plate 51 -19and stationary die plate 55 are being heated by the electric conductors 58 runing around them. The movable die plate 51 closes on the stationary die plate 55 and holds the solid cleanser holder positioned therebetween within the die sockets 57 and heat seals together the bottom and top films around the solid cleanser at the peripheries of the die sockets. Ports b and d and ports a and e of valve 67 of solid cleanser holder cutting unit are connected. Air flows into the piston side and air flows out into the atmosphere from the -cylinder side of cylinder 60 of the solid cleanser holder cutting unit. The piston 63 of cylinder 60 along with the punch plate 69 moves down towards the stationary die plate 80. The punch plate 69 closes on the die plate 80 and holds the solid cleanser holder positioned therebetween within the die cavities and cuts the solid cleanser holder at the peripheries of the die cavities. On being cut and separated from the bottom and top films, the solid cleanser holder 160 falls down through the open bottom of the die cavity 82 in the die plate 80 and corresponding opening 83 in the bese 81 of the supporting structure 62. While the punch plate 69 closes on the die plate and cuts and separates the solid cleanser holder from the films, the retainer flange 78 presses against the flbns under spring tension and holds thle lilrns in position to facilitate cutting of the solid cleanser holders. The rietainer'flang slde i ad out on the punch plte due to isbeing tensioned by springs 79 aid fixed to the screw members 75 which are movably disposed in the holes The outward movement of the screw members in holes 73 and hence that of the retainer flange is restricted by shoulders 77 as the heads of the screw members abuts the shoulders at the extrme outward position of the strew memibers. The size of the edges or frills of the solid cleaniser holder from the sealing point thereof depends on the larger -Peripheries of the die cavities as compared to the die sockets. At the end of the half cycle of operation of the arramgement, th Ie position of the pinion. 121 of the Geneva driver 117 Is as shown in Fig 17. The pinion 121 is about to enter slot 119f of the Geneva wheel 116. Dufing fuxiher rotation of the Geneva -driver. in the -anticlockwise direction the pinion 121 truvels into the slot 1 19f of the Genevu wheel (Fig 18) and travcls back from the slot 1 19f of the Geneva wheel and pbsitions itself at the mouth of slot 1 19f of the Guneva wheel as shown in Fig 19. During this half cycle drive is transmitted to the Geneva wheel and it -21rotates in the clockwise direction. Consequently drive is tranmitted to the solid cleanser feed conveyor 2.solid cleanser holder forming* unit 31 Comprising contrarotatable conveyors 32 and 33, Mim pulling units 100a, 1001b, 100c and 100d and film, scorn unit 84 and waste film caxrying unit 98.

Solid cleansers 158 being fed from the feed end of the conveyor 2 in the pockets formed by pairs of spaced upright members 4, ame moved forward by the feed conveyor. Due to momentum of m ovenmn of the feed conveyor, flhe solid cleanser at the discharge end of the infeed conveyor is pushed by the advancing -upright member 4. at the rear side of the solid cleanser 158 into the laminated bottom film 157 at the feed end 37a between die contrarotatable conveyors 32 and 33 over the flat protrusion 40. The contrarotating rollers of the film pullng units 100a and 100b pull the la-ninated bottom and top fIlms from the laminalion units Ila and hib and kcep them taut. In the solid cleanser holder forming unit 31, the bottom film is 57 arrying th oi lanses and the top film 157 overlying the solid cleanscis form holders for he solid cleansers and are moved forward by and between the contrarotatig conveyors 32 and 33. The bottom and top films -22having the solid cleaners interposed therebetween enter the solid cleanser holder scaling unit 41. The contrarotating rollers of the film pulling unit 100c Pull the bottom-n and top film with the scaled solid cleaners holders emerging from the solid cleanser holder scaling unit, and feed them to the solid cleanser cutting-unit. 59 one at a time. The contiarotatng rollers of the fim j~ulling unit 100d pull the bottom and top films from the solid cleanser cutting unit 59 through the film scoring unit 84 in which the rotary disc cutter 91 cuts or scores the waste film into two lengthwise, which remain as webs between ajascent cutouts of solid cleanser holders after they are cut and l0 scparated. The waste films emerging from. the pullin unit 100d are caried onto the waste film carrying conveyor 98. The waste films are cut and removed from the waste film currying conveyor as and when require d.

Simultaneously ports b and c and ports a and -d of valves 20 ate connected.

Air flows iiito the cylinder side anid air flows out into the atmosphere from the piston side of the cyliders 12 of Lhe fihm lamination units. 1Ila and I lb.

The piston 15 of the cylinders 12 move up into their original position. Ports b and c mnd ports a and d of valve 49 are connected. Aix flows into the -23cylinder side and air flows out into the atmosphere from the piston side of cylinder 42 of the solid cleanser holder sealing uinit 4 1. The piton 45. of cylinder 42 moves up to its original position- Por~ts b and c and ports a and d of value 67 are connected. Air flows into the cylindcr side and air flows out into the atmosphere from the piston side of cylinder 60 of the solid ceanser holder cutting unit 59. The piston 63 of the cylinder 60 moves up to its origna position. The arrangement is now ready for the next cycle of operation.

Du~e to the intcrmittent drive and feedinS of solid cleanser into the solid cleanter holder fornling unit in a cycle of operation of the arragment a gap is maintai ned between two solid cleansers in the solid canserhle omn ~i .,The temperature conrolers sense the tenipcrutze s of the laminator plates and movable die plate and corresponding Ationary die plate throughi the thermostats and cut of the power supply when die tcmpcratu-es exceed the set limits. The film tensioning rollers keep the film under tension. The busesare to minimise -24friction between the guide plutes mnd respective guide rods and render the up and down movement of the guide plates smooth.

The film lamination units, solid cleansr holder forming unit, solid cleanser holder sealing unit, solid cleanser holder cuffing unit, film pulling units, film scoring unit mid solid cleanser pockets mayibe of different .onstructions. There many be more than four film 'pulling units., Instead of.

pneumatic cylinders, hydraulic cylinders may be used. There may lemore thian two film unwind top rolls and mor Ie than two film unwind bottom rolls and corresponding number of fims to be lmanited. The was te film carrying.

conveyor a=d film scoring unil are optiond. Instead of waste film carrying conveyor some other arrangement may be used to carry the used films. The sizes and profiles of the die sockets and die cavities will change depending upon the sizes and profiles of the solid cleansers mid solid cleans er holdexs.

The arrangement may include a solid clean-ser feeding unit. Instead. of Sim.

unwind rolls, the film feeding wrmgsment may be different. Such variatons of the invention are t6 be construed mnd understood to be within the scope of the invention