Transfer pack having compressible surface material

Abstract

The apparatus (10) includes a transfer mechanism (12) for transferring individual articles (50) to a receiving member (54). The transfer mechanism includes a plurality of transfer packs (18) for carrying the individual articles thereon. Each of the transfer packs includes a pack body (60) having an article conveying surface with vacuum holes formed therein for holding the individual articles thereon via vacuum. The article conveying surface includes a central region and at least one side region adjacent the central region, the side regions being aligned longitudinally along the pack body. Each of the transfer packs also includes one or more resilient puck inserts (64) disposed about a portion of the periphery of the transfer pack, each puck insert engaging the pack body at a respective side region. The puck inserts are sized to protrude above the article conveying surface and are depressible inwardly toward the article conveying surface upon application of force.

Description

[Technical field]

[0001] Embodiments of the present invention relate to apparatus for transporting individual components or articles as they advance along a production line, and more particularly, to transfer packs employed in such apparatus that include compressible or flexible surface members that aid in the transport of the individual components from the transfer pack. [Background technology]

[0002] In the production and manufacturing of various products, it is often necessary to manufacture one component of the product and then transport it to another location for use in another step of the manufacturing process. In the example of a disposable absorbent product such as a diaper, a separate component such as an absorbent core or insert may be manufactured at a first location and then transported to a second location onto a receiving surface that may comprise one or more movable webs of components, such as the webs of the front and back belt portions.

[0003] The above-mentioned transfer of the individual components is accomplished by a transfer device employing a puck that holds the individual components and performs a controlled transfer between pick-up and drop-off locations, where the puck assists in proper application and bonding of the individual components to the receiving surface. A typical transfer device functions to receive or form the individual components at a receiving location and to transfer the components for placement on the receiving surface at a placement location. Additionally, the device may also function to spin the components to a predetermined angle and / or control the speed and pitch between the components to achieve a desired position pitch on the receiving surface.

[0004] The transfer apparatus may comprise a large wheel ("puck wheel") with multiple rotating pucks fixed thereto that are selectively operable to provide transfer and optional spinning and re-pitching of the individual components. The puck wheel is driven and supported by a shaft extending from the drive side of the apparatus, and the transfer pucks then rotate with the wheel. Additionally, each transfer puck functions to spin / rotate about its own spin axis to provide rotation (e.g., 90 degree rotation) of the individual items. In operation, the individual components are received by the transfer pack at a receiving location, and the transfer pack secures the components by vacuum as the transfer pack rotates (and spins about its spin axis) with the puck wheel from the receiving location to the placement location. At the receiving location, the vacuum on the transfer pack may be turned off to release the individual components onto a receiving surface.

[0005] The above-described operation of the transfer device, which selectively activates and deactivates the vacuum to hold the individual components on the transfer pack and then releases the individual components from the transfer pack onto the receiving surface, is known to be effective for the transfer of many components, including the transfer of absorbent pads used in disposable products. However, it has been recognized that for some components, the characteristics of the component may inhibit the ability of the transfer pack to properly release and transfer the component onto the receiving surface via the cessation of the vacuum at the pack surface. That is, for components of increased size, thickness, and / or material density, for example, the component may not be released from the transfer pack as easily as a component having a smaller size, thickness, or material density, which is due (at least in part) to the cessation of the vacuum or the reversal of air flow through the pack surface (i.e., blow-off), and the effect of separating the component from the pack surface is less dramatic. Although the individual components can be more forcibly transferred onto the receiving surface at the placement location, such as by applying a force to push the transfer pack and the component down onto the receiving surface, the application of such a force may damage the component or the receiving surface (e.g., receiving a web) due to the rigid structure of the transfer pack.

[0006] It is therefore desirable to provide a transfer pack, and overall transfer apparatus, that provides efficient transfer of a wide range of individual components to a receiving surface to accommodate the transfer of individual items of different types and sizes. The transfer pack ensures that the individual components are transferred accurately onto the receiving surface and without damaging the individual components or the receiving surface, even when forces are applied during application and transfer of the individual components. Summary of the Invention

[0007] Embodiments of the invention are set out and characterized in the independent claims, while the dependent claims describe further features and variants of the invention, which features and variants recited in the dependent claims can be used in combination with one another or separately, depending on the embodiments of the invention.

[0008] According to some embodiments, the apparatus includes a transfer mechanism configured to transfer a plurality of individual items from an item receiving location to an item placement location, the transfer mechanism including a plurality of transfer units moving along a transfer path from the item receiving location to the item placement location, each of the plurality of transfer units including a transfer pack selectively operable to carry an individual item thereon as the transfer pack moves between the item receiving location and the item placement location. The apparatus also includes a receiving member disposed at the item placement location to receive the plurality of individual items from the transfer mechanism. Each transfer pack includes a pack body having a back surface and an item transport surface having vacuum holes formed therein for holding the individual items thereon via vacuum, the item transport surface including a central region and at least one side region adjacent the central region, the at least one side region being aligned longitudinally along the pack body. Each of the transfer packs also includes a pack insert configuration including one or more pack inserts disposed around a portion of the circumference of the transfer pack, each of the one or more pack inserts being dimensioned to engage the pack body at a respective side region and to protrude above the item transport surface. Each of the one or more puck inserts is a resilient structure depressible inwardly toward the article-conveying surface upon application of a force.

[0009] In some embodiments, the puck insert arrangement includes a pair of puck inserts.

[0010] In some embodiments, the at least one side region includes a pair of side regions on either side of the central region, the pack body includes an insert channel formed in each side region of the pair of side regions, and a pack insert of the one or more pack inserts slidably engages with each respective insert channel.

[0011] In some embodiments, the device further comprises an end cap secured to at least one end of the puck body, the end cap closing the insert channel to secure the puck insert within the insert channel.

[0012] In some embodiments, the puck body includes one or more vacuum channels formed therein to provide a fluid flow path for vacuum from the back surface to the vacuum holes in the article transport surface, and each of the one or more puck inserts includes a hollow member defining an internal chamber, the internal chamber being in fluid communication with the vacuum channel of the puck body.

[0013] In some embodiments, each of the one or more puck inserts comprises a top wall having a vacuum hole formed therein, a bottom wall having one or more openings formed therein, and a pair of side walls disposed between the top wall and the bottom wall and spacing the top wall from the bottom wall, wherein the top wall, bottom wall, and pair of side walls define an internal chamber, and a vacuum communicates from a vacuum channel in the puck body, through the openings in the bottom wall, and through the internal chamber to the vacuum hole in the top wall.

[0014] In some embodiments, the one or more puck inserts each comprise a trapezoidal shaped member having a pair of parallel side walls.

[0015] In some embodiments, for each of the one or more pack inserts, the top wall slopes from an upper edge disposed adjacent the central region to a lower edge disposed adjacent a longitudinal edge of the pack body.

[0016] In some embodiments, the one or more puck inserts each comprise a bellows-shaped member that flexes inwardly and depresses upon application of force.

[0017] In some embodiments, each of the one or more puck inserts is constructed from rubber, silicone rubber, polyurethane, thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or neoprene foam.

[0018] In some embodiments, the transport mechanism is configured to forcibly contact each of the multiple transport units with the receiving member at the article placement location to transfer the multiple individual articles onto the receiving member, the forcible contact pressing the elastic structure inwardly toward the article conveying surface.

[0019] In some embodiments, the pack insert configuration comprises a single pack insert disposed at a leading edge of the transfer pack that first contacts the receiver member at the item placement location.

[0020] According to another embodiment, a transfer pack for transferring and placing individual articles on a receiving surface is provided. The transfer pack comprises a pack body having a back surface and an article conveying surface having vacuum holes formed therein for holding individual articles thereon via vacuum, the article conveying surface comprising a central region and at least one side region adjacent the central region, the at least one side region being aligned longitudinally along the pack body. The transfer pack also comprises a pack insert arrangement including one or more pack inserts disposed about a portion of the periphery of the transfer pack, each of the one or more pack inserts engaging the pack body at a respective side region and projecting above the article conveying surface. Each of the one or more pack inserts is a resilient structure depressible inwardly toward the article conveying surface upon application of force.

[0021] In some embodiments, the at least one side region includes a pair of side regions disposed on either side of the central region, the pack body including an insert channel formed in each respective side region of the pair of side regions, and each pack insert of the one or more pack inserts slidably engaging with a respective insert channel.

[0022] In some embodiments, the puck insert arrangement includes a pair of puck inserts, each puck insert of the pair engaging a respective insert channel.

[0023] In some embodiments, the puck body includes one or more vacuum channels formed therein to provide a fluid flow path for vacuum from the back surface to the vacuum holes in the article transport surface, and each of the one or more puck inserts includes a hollow member defining an internal chamber, the internal chamber being in fluid communication with the vacuum channel of the puck body.

[0024] In some embodiments, each of the one or more puck inserts comprises a top wall having a vacuum hole formed therein, a bottom wall having one or more openings formed therein, and a pair of side walls disposed between the top wall and the bottom wall and spacing the top wall from the bottom wall, wherein the top wall, bottom wall, and pair of side walls define an internal chamber, and a vacuum communicates from a vacuum channel in the puck body, through the openings in the bottom wall, and through the internal chamber to the vacuum hole in the top wall.

[0025] In some embodiments, for each of the one or more pack inserts, the top wall slopes from an upper edge disposed adjacent the central region to a lower edge disposed adjacent a longitudinal edge of the pack body.

[0026] In some embodiments, the one or more puck inserts each comprise a bellows-shaped member that flexes inwardly and downwardly upon application of force.

[0027] In some embodiments, the central region includes a recessed region and each of the side regions and the one or more puck inserts protrudes above the recessed region.

[0028] According to yet another embodiment, there is provided a method of transferring individual items from a transfer pack to a receiving surface. The method includes holding the individual items on an item transport surface of a transfer pack via a vacuum communicating through the transfer pack, the transfer pack comprising one or more puck inserts attached to the item transport surface at one or more side regions thereof so as to be disposed around a portion of a circumference of the transfer pack, each of the one or more puck inserts comprising a resilient structure protruding above the item transport surface and depressible inwardly towards the item transport surface upon application of a force to the item transport surface. The method also includes transferring the individual items from the transfer pack to a receiving surface at an item placement location, the transferring of the individual items comprising contacting the individual items held on the item transport surface to the receiving surface at the item placement location and applying a pressing force from the transfer pack to the receiving surface as the individual items contact the item transport surface to transfer the individual items from the item transport surface to the receiving surface. The pressing force depresses the one or more puck inserts inwardly towards the item transport surface.

[0029] In some embodiments, the pressing force depresses a puck insert of one or more puck inserts disposed at a leading edge of the transfer pack that first contacts the receiving surface at the item placement location.

[0030] In some embodiments, the pressing force depresses a puck insert of one or more puck inserts disposed at a trailing edge of the transfer pack opposite the leading edge.

[0031] In some embodiments, the vacuum communicated through the transfer pack is through vacuum holes formed in the article transport surface and in one or more puck inserts.

[0032] These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention, which are provided in connection with the accompanying drawings. [Brief description of the drawings]

[0033] The drawings illustrate embodiments presently contemplated for carrying out the invention.

[0034] In the figure,

[0035] [Figure 1] 1 is a front view of a cutting and transporting device in which embodiments of the present invention may be implemented, in accordance with an embodiment of the present invention;

[0036] [Figure 2A] 2 is a top perspective view of a transfer pack included in the apparatus of FIG. 1 in accordance with an embodiment of the present invention. [Figure 2B] 2 is a bottom perspective view of a transfer pack included in the apparatus of FIG. 1 in accordance with an embodiment of the present invention.

[0037] [Diagram 3] FIG. 2C is an exploded view of the transfer pack of FIGS. 2A and 2B, showing the pack insert and end cap exploded from the pack body.

[0038] [Figure 4] 4 is a cross-sectional view of the transfer pack of FIG. 2A taken along line 4-4.

[0039] [Figure 5A] 3 is a top perspective view of a pack insert included in the transfer pack of FIG. 2. [Figure 5B] FIG. 2C is a bottom perspective view of a pack insert included in the transfer pack of FIG. 2B.

[0040] [Figure 6A] 2 is a top perspective view of a transfer pack included in the apparatus of FIG. 1 according to another embodiment of the present invention. [Figure 6B] 2 is a bottom perspective view of a transfer pack included with the apparatus of FIG. 1 in accordance with another embodiment of the present invention.

[0041] [Figure 7]FIG. 6C is an exploded view of the transfer pack of FIGS. 6A and 6B, showing the pack insert and end cap exploded from the pack body.

[0042] [Figure 8] 8 is a cross-sectional view of the transfer pack of FIG. 6 taken along line 8-8.

[0043] [Figure 9A] FIG. 6B is a top perspective view of a pack insert included in the transfer pack of FIG. 6A. [Figure 9B] FIG. 6C is a bottom perspective view of a pack insert included in the transfer pack of FIG. 6B.

[0044] [Figure 10] 2 is a perspective view of a transfer pack included with the apparatus of FIG. 1 in accordance with an embodiment of the present invention.

[0045] [Figure 11A] 1 is a side schematic view of a puck interacting with a receiver member during transfer of individual articles, according to an embodiment of the present invention. [Figure 11B] 1 is a side schematic view of a puck interacting with a receiver member during transfer of individual articles, according to an embodiment of the present invention. [Figure 11C] 1 is a side schematic view of a puck interacting with a receiver member during transfer of individual articles, according to an embodiment of the present invention. [Figure 11D] 1 is a side schematic view of a puck interacting with a receiver member during transfer of individual articles, according to an embodiment of the present invention.

[0046] [Figure 12] 1 is a product turner and placer in accordance with an embodiment of the present invention, in which embodiments of the present invention may be implemented; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0047] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention relates to a compressible transfer pack for use with a cutting and transferring device or pick and place system to facilitate the transfer of individual items. The disclosure herein is provided in sufficient detail to enable one skilled in the art to practice the invention, but the physical embodiments disclosed herein are merely illustrative of the invention which may be embodied in other specific configurations. Although preferred embodiments have been described above, details may be changed without departing from the invention.

[0048] Referring to FIG. 1, a cutting and transporting apparatus 10 (or "apparatus 10") is shown in which embodiments of the present invention may be implemented. Apparatus 10 preferably includes a transport mechanism 12 and a cutting system 14. Transport mechanism 12 includes a plurality of transport units 16 each including a transport pad or puck 18 (hereinafter referred to as a "transport puck 18") that may be engaged and disengaged therefrom. Transport units 16 are coupled to (and are movable with) a mounting structure of transport mechanism 12, which in the exemplary embodiment is a center plate 20. Transport units 16 and center plate 20 collectively form a puck wheel 22 of a desired configuration. In the illustrated embodiment, puck wheel 22 includes a total of nine transport units 16 and transport pucks 18 disposed on center plate 20, although it will be appreciated that more or fewer transport units 16 and transport pucks 18 may be provided.

[0049] The central plate 20 is fixedly coupled to a motor drive shaft 24 that provides a substantially operationally constant rotational force to the central plate 20. The central plate 20, together with the transfer units 16 and the transfer packs 18 attached thereto, are thus rotated about a longitudinal axis of rotation, a pack transfer axis 26, to move the transfer packs 18 about a transfer path 28. As used throughout the description of the preferred embodiment, "rotate" and variations thereof refer to the movement of the entire transfer packs 18 (and transfer units 16) about the transfer axis 26, and "spin" and variations thereof refer to the radial spinning of the transfer packs 18 about a pack spin axis 30 that is substantially perpendicular to the pack transfer axis 26, as will be further described below. A vacuum system 32 is also provided in the apparatus 10 that provides a vacuum to the individual transfer units 16 and transfer packs 18 of the transfer mechanism 12. Vacuum is transferred from the area of ​​the central plate 20 to the transfer units 16 via a number of vacuum passages or vacuum tubes (not shown) coupled therebetween.

[0050] As shown in FIG. 1, the cutting system 14 preferably includes an anvil wheel 34 and a knife roll 36 that interact with each other to cut individual articles from a continuous web provided to the cutting and transferring device 10. Although the cutting system 14 is described herein as including an anvil wheel 34 and a knife roll 36, it is recognized that these components may be reversed utilizing a knife wheel and anvil roll as compared to the illustrated embodiment. The anvil wheel 34 includes a central anvil hub 38 from which a plurality of anvil arms 40 extend radially outwardly for a range of approximately 360° of the anvil wheel 34. Each of the anvil arms 40 includes an anvil 42 at its end that is configured to interact with one or more knife blades 44 on the knife roll 36 to cut the material when the respective anvil 42 is positioned at a cutting location adjacent the knife blade 44. In an alternative embodiment, the multiple anvil arms 40 of the anvil wheel 34 may be replaced with a single contact surface.

[0051] In operation, the apparatus 10 receives a continuous web 46 from a source, which contacts the transfer pack 18 at a receiving location 48. One of the anvils 42 is then rotated into position to be aligned with (i.e., in contact with) a knife blade 44 on the knife roll 36 to sever the web 46 adjacent the leading edge of the transfer pack 18. After receiving the web 46 and the cut made adjacent the leading edge, the transfer pack 18 advances along the transfer path 28 past the knife roll 36, at which point the next anvil 42 on the anvil wheel 34 rotates into position to cooperate with the knife blade 44 to cut the web 46 adjacent the trailing edge of the transfer pack 18 to sever individual portions therefrom to form individual articles 50, such as inserts or pads. The individual articles 50 are supported by the vacuum on the transfer pack 18 and rotated about the transfer path 28 to an article placement location 52 where the portions are transferred from the transfer pack 18 to a receiving surface or member 54, as described in more detail below.

[0052] The speed and positioning of the transfer units 16 relative to one another (i.e., the pitch between the transfer units 16) may be controlled as they rotate about the transfer path 28, and the individual articles 50 can then be placed at a desired pitch on the receiving member 54. That is, the transfer units 16 of the transfer mechanism 12 are movably coupled to the central plate 20. Each of the transfer units 16 (and the transfer packs 18 thereon) can be displaced circumferentially relative to the central plate 20 in the machine direction 55 to allow for pitch variations or altered circumferential spacing of the transfer packs 18.

[0053] In addition to providing rotation of the transfer units 16 and transfer packs 18 about the transfer axis 26, the transfer mechanism 12 also provides radial spinning of each transfer pack 18 about a pack spin axis 30. According to one embodiment, the radial spinning of each transfer pack 18 may be a ninety degree (90°) pack rotation, although it will be recognized that other amounts of pack rotation may be provided by the transfer mechanism 12.

[0054] At the article placement location 52, the individual articles 50 are transferred onto a receiving surface or member 54, which according to various embodiments may be a web of material, a drum, a conveyor belt, or a web of material moving on a drum or conveyor belt, for example. In an exemplary embodiment, the receiving member 54 is a web of material that is conveyed around the surface of a rotating transfer drum 56 at the placement location 52. An adhesive dispenser 59 may be used to apply adhesive 58 to the web 54 upstream of the transfer drum 56. The adhesive 58 may be applied to a portion of the web 54 before the web 54 moves on the transfer drum 56. As a result, the individual articles 50 being transferred to the web 54 (while on the transfer drum 56) may be adhesively attached to the web 54.

[0055] According to an embodiment, it is recognized that it may be desirable to transfer the individual articles 50 from the transfer pack 18 to the receiver member 54 by forcing the individual articles 50 onto the receiver member 54. When the transfer pack 18 carrying the individual articles 50 reaches the article placement location 52, the transfer pack 18 contacts the receiver member 54. The transfer pack 18 and receiver member 54 are positioned at the article placement location 52 such that the transfer pack 18 presses against the receiver member 54 with a desired amount of transfer force. Thus, in one embodiment, the individual articles 50 contact and are pressed into the adhesive 58 provided on the receiver member 54 (i.e., the web of material) to secure the individual articles 50 in place on the receiver member 54.

[0056] To better accommodate and enable this forcible transfer of the individual articles 50 to the receiving member 54, the transfer pack 18 includes one or more resilient surface members, hereinafter referred to as a pack insert configuration. The pack insert configuration includes one or more resilient insert members disposed on the article conveying surface of the transfer pack 18 to help adhere, attach, adhere or bond the individual articles 50 to the receiving member 54. The resilient insert member(s) are configured to be forced inwardly toward the article conveying surface of the transfer pack 18 upon application of pressure, such as when a compressive force is applied during transfer of the individual articles 50 to the receiving member 54.

[0057] 2A, 2B, 3, 4, 5A and 5B, and with continued reference to FIG. 1, the structure of a transfer pack 18 that may be included with the apparatus 10 is shown, along with its individual components / parts, according to an embodiment. The transfer pack 18 is generally constructed of a pack body 60 and a pack insert arrangement 62 that mates with the pack body 60. The pack insert arrangement 62 includes one or more resilient pack inserts 64, e.g., two inserts in the illustrated embodiment. As discussed above, the resilient pack inserts 64 can aid in transferring the individual articles 50 from the transfer pack 18 and securing the individual articles 50 in place relative to the receiving member 54. The resilient pack inserts 64 are forced inwardly by applied pressure, such as when a compressive force is applied to the resilient pack inserts 64 while transferring the individual articles 50 onto the receiving member 54.

[0058] The puck body 60 is constructed from a rigid material and may be formed as a single, unitary body structure or through the joining of multiple components to form the puck body 60. The puck body 60 includes an article conveying face 66 and an opposing back face 68. The article conveying face 66 of the puck body 60 is configured to engage the individual articles 50 and facilitate transferring the articles onto the receiving member 54. The back face 68 of the puck body 60 is configured to engage the transfer pucks 18 with their respective transfer units 16 and communicate a vacuum to the transfer pucks 18.

[0059] As shown in FIG. 2B, the back surface 68 of the transfer pack 18 includes a configuration of openings 70 that allow for vacuum communication between the transfer pack 18 and the vacuum system 32 within the apparatus 10. The openings 70 in the back surface 68 of the pack body 60 are fluidly coupled with one or more vacuum passages 72 (FIG. 4) formed within the pack body 60. The vacuum passages 72 are in fluid communication with the article conveying surface 66 and the vacuum holes 74 (e.g., FIGS. 2A and 3) in the pack insert 64 such that vacuum can be diverted through the transfer pack 18. Although not shown in FIG. 2B, it will be appreciated that the back surface 68 of the transfer pack 18 also includes a pack connector that couples the transfer pack 18 to the transfer unit 16. In one example, such a pack connector can be configured as a "quick connect" type connector that allows the transfer pack 18 to be easily swapped and replaced on the transfer unit 16 based on the particular setup of the transfer mechanism 12. The pack connector also forms a vacuum channel therein that aligns with the openings 70 in the back surface 68.

[0060] The article conveying surface 66 of the transfer pack 18 may be generally characterized as comprising a central region 76 and a pair of side regions 78. The side regions 78 are longitudinally aligned along the pack body 60 (i.e., extending parallel to the longitudinal edges 80 of the pack body 60) and disposed on either side of the central region 76. In the illustrated embodiment, the central region 76 is defined by a recessed interior region 82 and a raised rim 84 forming a perimeter around the recessed interior region 82 to accommodate positioning of the individual articles 50 on the article conveying surface 66, particularly where the article has an increased thickness. In other embodiments, the central region 76 may present a flat or substantially flat article conveying surface (as illustrated by surface 136 in FIG. 6A) or an arcuate article conveying surface. In one embodiment, each of the opposing ends of the central region 76 includes a plurality of vacuum holes 74 formed therein, the vacuum holes extending through the article conveying surface 66 to be in fluid communication with the vacuum passages 72 formed within the interior of the pack body 60.

[0061] Each side region 78 of the article conveying surface 66 is constructed to form an insert channel 88 therein that extends longitudinally along the pack body 60. The insert channels 88 are formed to extend along the entire length of the pack body 60, and each insert channel 88 may be defined on one side by an edge wall 90 disposed at / adjacent to the longitudinal edge 80 of the pack body 60 and on the other side by an inner wall 92 that extends downwardly from the rim 84 of the central region 76. In one embodiment, the edge wall 90 may be shorter than the inner wall 92 such that the edge wall 90 is disposed at a lower level than the rim 84 of the central region 76. The insert channel 88 is closed at one end by an end wall 94 of the pack body 60 and the opposite end of the insert channel 88 is closed by an end cap 96 that is secured to the pack body 60 (e.g., via fasteners 98) following insertion of the pack insert 64 into the insert channel 88. The insert channel 88 is constructed to be in fluid communication with one or more vacuum passages 72 formed within the interior of the puck body 60, and has a bottom surface of the insert channel 88 and / or an interior surface of the channel (i.e., interior wall 92) with an opening or open area 100 that allows for the transfer of vacuum between the vacuum passages 72 and the insert channel 88. One or more mating grooves 102 and ridges 104 may be provided in each of the insert channels 88 extending along the length of the channel. The mating grooves 102 and ridges 104 are configured to mate with corresponding features of the puck insert 64 to retain the insert in the insert channel 88, as described in further detail below.

[0062] 2-5 as including a pair of channels 88 formed in the article conveying surface 66, it will be appreciated that other embodiments of the pack body 60 may include only a single channel 88 formed in one side region 78. More specifically, the insert channel 88 may be formed in a side region 78 that is determined to be a leading edge 80a of the transfer pack 18 (opposite a trailing edge 80b) that will first contact the receiving member 54 as the transfer pack 18 translates to the article placement location 52.

[0063] As previously discussed, the transfer pack 18 includes a puck insert arrangement 62 that mates with the pack body 60. In the illustrated embodiment, the puck insert arrangement 62 includes a pair of puck inserts 64, one corresponding to each side region 78 (and insert channel 88) of the pack body 60. However, it will be appreciated that the puck insert arrangement 62 could instead include only a single puck insert 64, with the puck insert 64 corresponding to a side region 78 (and insert channel 88) formed adjacent the front edge 80a of the transfer pack 18, as previously discussed. Other embodiments of the transfer pack 18 could include a greater number of puck inserts 64 (e.g., four inserts), such as where multiple puck inserts 64 correspond to each insert channel 88. Thus, with one or more puck inserts 64 provided in one or more associated side regions 78 of the pack body 60, the puck insert(s) 64 are positioned about a portion of the perimeter 106 of the transfer pack 18, with the central region 76 of the pack body 60 not having a puck insert 64 positioned therein.

[0064] As best shown in FIGS. 3-5, each of the puck inserts 64 is constructed as a generally bellows-shaped member including a top wall 108, a bottom wall 110, and a pair of side walls 112. The pair of side walls 112 are inserted from the edges of the top wall 108 and bottom wall 110 and are formed as curved walls that can flex inwardly and outwardly when pressure is applied to the puck insert 64. The side walls 112, along with a portion of the top wall 108 and bottom wall 110, define an interior chamber 114 formed within the puck insert 64 such that the puck insert 64 is constructed as a hollow or semi-hollow member. The top wall 108 of the puck insert 64 includes a plurality of vacuum holes 74 formed therein by which vacuum suction may be applied to the individual articles 50 held on the transfer puck 18. The bottom wall 110 of the puck insert 64 includes a plurality of openings 116 (FIG. 5B) formed therein that are aligned with the open areas 100 of the insert channels 88. Each of the vacuum holes 74 and openings 116 are in fluid communication with an interior chamber 114 of the puck insert 64, so that vacuum may be transferred through the puck insert 64. Thus, vacuum may be communicated from the vacuum passages 72 in the puck body 60, through the open area 100 of the insert channel 88, through the openings 116 in the bottom wall 110, so that the vacuum is further communicated through the interior chamber 114 to the vacuum holes 74 formed through the top wall 108 of the puck insert 64. In one embodiment, as shown in Figures 2A and 3, a denser pattern of vacuum holes 74 is provided at opposing ends of the puck insert 64 to provide greater retention force for the corners of the individual articles 50 (Figure 1) secured to the transfer puck 18.

[0065] When the puck inserts 64 are secured to the puck body 60, each of the puck inserts 64 seats in a respective insert channel 88 in the article conveying surface 66. The mating grooves 102 and ridges 104 in each of the insert channels 88 are configured to secure the puck insert 64 in place within the insert channel 88 via engagement with a bottom wall 110 of the puck insert 64. That is, the space defined between the mating grooves 102 and the ridges 104 of the insert channel 88 defines a track 118 in which the bottom wall 110 of the puck insert 64 seats. As previously mentioned, the pair of curved side walls 112 are inserted from the edge of the bottom wall 110 such that the bottom wall 110 can project laterally outward therefrom and engage the track 118 defined by the mating grooves 102 and ridges 104 of the insert channel 88. The raised portion 104 of the insert channel 88 provides a penetration 120 into which the side wall 112 is positioned, and the bottom wall 110 is secured to a track 118 therebelow, thereby effectively locking the puck insert 64 in the insert channel 88 and securing the puck insert 64 relative to the puck body 60. As best shown in FIG. 4 , when seated in the insert channel 88, a gap 122 exists between the top wall of the puck insert 64 and the raised portion 104 of the insert channel 88. This gap 122 beneath the top wall 108 allows the top wall 108 to be forced inwardly when a compressive force is applied to the puck insert 64, such as may occur when an individual article 50 is transferred and pressed against the receiver member 54.

[0066] The transfer pack 18 is constructed such that when the puck insert 64 is seated in the insert channel 88 of the pack body 60, the puck insert 64 extends upwardly beyond the level of the article conveying surface 66 (i.e., upwardly past the side regions 78 and the central region 76 of the article conveying surface 66). As shown in FIG. 4, the height H that the top wall 108 of each puck insert 64 extends above the article conveying surface 66 can be determined, at least in part, by the compressibility of the puck insert 64 and how much they compress inwardly when a force is applied. In an exemplary embodiment, the top wall 108 of each puck insert 64 is provided as an angled member configured to generally match the contour of the puck body 60 (the rim 84 of the central region 76 is elevated relative to the edge walls of the side regions 78). That is, the top wall 108 of each puck insert 64 is angled such that it slopes downwardly from an upper edge 124 located adjacent the central region 76 to a lower edge 126 located adjacent the longitudinal edge 80 of the puck body 60. When tilted as described above, the angled top wall 108 of the puck insert 64 aids in the transfer of the individual articles 50 from the transfer pack 18 to the receiving member 54. For example, with the puck insert 64 positioned at the leading edge 80a of the transfer pack 18, the bottom edge 126 of the top wall 108 will be first in contact with the receiving member 54 as the transfer pack 18 translates to the article placement location 52. With the top wall 108 tilted upward from the bottom edge 126, the puck insert 64 (with the individual articles 50 still positioned thereon) will be in rolling contact with the receiving member 54 such that the pushing force applied from the transfer pack 18 towards / to the receiving member 54 is applied in a rolling manner, thus resulting in efficient transfer of the individual articles 50 from the transfer pack 18 to the receiving member 54.

[0067] The puck insert 64, including the top wall 108, the bottom wall 110, and the pair of side walls 112, is constructed from a compressible, resilient material that allows the puck insert 64 to be depressed when a force is applied. Thus, according to an embodiment, the puck insert 64 may be constructed from one or more compressible, deformable, and / or resilient materials, such as, by way of non-limiting example, rubber, silicone rubber, polyurethane, thermoplastic polyamide (TPA), thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or neoprene foam. The resilient puck insert 64 is configured to push inwardly toward the article conveying surface 66 of the transfer pack 18 upon application of pressure, such as when a compressive force is applied during transfer of the individual articles 50 to the receiving member 54. The resilient puck insert 64 returns to its original configuration when the compressive force is removed, such as after the individual articles 50 are transferred onto the receiving member 54.

[0068] In embodiments, it may be desirable to use a material such as silicone rubber on at least the top wall 108 or top surface of the puck insert 64 to provide a non-stick surface that resists adhesive build-up, such as may be present on the receiving member 54 (e.g., a web material) onto which the individual articles 50 carried by the transfer pack 18 are transferred. For example, in some instances, when the individual articles 50 are pressed onto the web by the transfer pack 18, the adhesive on the web may seep through the individual articles 50 onto the puck insert 64.

[0069] The puck inserts 64 may be manufactured by a 3D printing process or other suitable manufacturing technique. The puck inserts 64 are assembled into the puck body 60 by sliding the puck insert 64 into the insert channel 88 from its open end. A bottom wall 110 of each puck insert 64 mates with a track 118 defined in the respective insert channel 88. Once the puck insert 64 is placed into the insert channel 88, an end cap 96 is secured to the puck body 60 (e.g., via fasteners 98) to close the open end of the insert channel 88. Thus, the puck insert 64 is held between the end cap 96 and the closed end wall 94 at the opposite end of the puck body 60.

[0070] 6A, 6B, 7, 8, 9A and 9B, and with continued reference to FIG. 1, the structure of a transfer pack 18, along with its individual components / parts, that may be included with the apparatus 10, according to another embodiment, is shown. The transfer pack 18 is generally constructed of a pack body 130 and a pack insert arrangement 132 that mates with the pack body 130. The pack insert arrangement 132 includes one or more resilient puck inserts 134 therein, e.g., two inserts in the embodiment shown.

[0071] The puck body 130 includes an article conveying face 136 and an opposing back face 138. As shown in Figure 6B, the back face 138 of the transfer pack 18 includes an arrangement of openings 140 that provide vacuum communication from the vacuum system 32 in the apparatus 10 to the transfer pack 18. The openings 140 in the back face 138 of the puck body 130 are fluidly coupled with one or more vacuum passages 142 (Figure 8) formed within the interior of the puck body 130, which are in fluid communication with the article conveying face 136 and vacuum holes 144 (e.g., Figures 6A and 7) in the puck insert 134 such that vacuum can be diverted through the transfer pack 18.

[0072] The article conveying surface 136 of the transfer pack 18 may be generally characterized as comprising a central region 146 and a pair of side regions 148. The side regions 148 are longitudinally aligned along the pack body 130 (i.e., extending parallel to a longitudinal edge 150 of the pack body 130) and are disposed on either side of the central region 146. According to an embodiment, the central region 146 is provided as a flat or planar portion with a plurality of vacuum holes 144 formed therein, the vacuum holes extending through the article conveying surface 136 to be in fluid communication with vacuum passages 142 formed within the interior of the pack body 130. In the illustrated embodiment, the vacuum holes 144 are provided at opposite ends of the central region 146 of the article conveying surface 136, although additional vacuum holes 144 may be provided elsewhere in the central region 146.

[0073] Each side region 148 of the article conveying surface 136 is constructed to form an insert channel 152 therein that extends longitudinally along the pack body 130. The insert channels 152 are formed to extend along the entire length of the pack body 130, and each insert channel 152 may be defined on one side by an edge wall 154 disposed at / adjacent to the longitudinal edge 150 of the pack body 130 and on the other side by an inner wall 156 adjacent the central region 146. In one embodiment, the edge wall 154 may be shorter than the inner wall 156 such that the edge wall 154 is disposed at a lower level than the central region 146. The insert channel 152 is closed at one end by an end wall 158 of the pack body 130 and the opposite end of the insert channel 152 is closed by an end cap 160 that is secured to the pack body 130 (e.g., via fasteners 163) following insertion of the pack insert 134 into the channel 152. The insert channel 152 is constructed to be in fluid communication with one or more vacuum passages 142 formed within the interior of the puck body 130, and has a bottom surface of the insert channel 152 and / or an interior surface of the channel 152 with an opening or open area 162 that allows for the transfer of vacuum between the vacuum passages 142 and the insert channel 152. A mating groove 164 may be provided in each of the insert channels 152 extending along the length of the channel 152. The mating groove 164 is configured to mate with a corresponding feature of the puck insert 134 to retain the insert in the insert channel 152, as described in further detail below.

[0074] As previously discussed, the transfer pack 18 includes a puck insert arrangement 132 that mates with the pack body 130. In the illustrated embodiment, the puck insert arrangement 132 includes a pair of puck inserts 134, one for each side region 148 (and insert channel 152) of the puck body 130. As best shown in FIGS. 7-9, each of the puck inserts 134 is constructed as a generally trapezoidal shaped member including a top wall 166, a bottom wall 168, and a pair of side walls 170 that collectively define an interior chamber 172 formed within the puck insert 134 such that the puck insert 134 is configured as a hollow member. The top wall 166 of the puck insert 134 includes a plurality of vacuum holes 144 formed therein, whereby vacuum suction may be applied to the individual articles 50 held on the transfer pack 18. The bottom wall 168 of the puck insert 134 includes a plurality of openings 174 (FIG. 9B) formed therein that align with the open regions 162 of the insert channels 152. Each of the vacuum holes 144 and openings are in fluid communication with an interior chamber 172 of the puck insert 134 so that vacuum can be transferred through the puck insert 134. Thus, vacuum can be communicated from the vacuum passages 142 in the puck body 130, through the open area 162 of the insert channel 152, through the openings 174 in the bottom wall 168, so that the vacuum is further communicated through the interior chamber 172 to the vacuum holes 144 on the top wall 166 of the puck insert 134.

[0075] When securing the puck inserts 134 to the puck body 130, each of the puck inserts 134 seats in a respective insert channel 152 in the article conveying surface 136. The mating grooves 164 of each of the insert channels 152 are configured to secure the puck insert 134 in place within the insert channel 152 via engagement with a bottom wall 168 of the puck insert 134. That is, an angular protrusion 176 on the bottom wall 168 extends beyond the side wall 170 to engage with the grooves 164 of the insert channel 152 to effectively lock the puck insert 134 within the insert channel 152 and secure the puck insert 134 relative to the puck body 130. In one embodiment, the puck insert 134 can also be secured to the insert channel 152 using a fastener pin 178 which extends downwardly through a fastener opening 180 in the top wall 166, extends downwardly through the internal chamber 172 of the puck insert 134 and engages with a pin hole 182 formed in the side region 148 of the puck body 130 below the insert channel 152.

[0076] As best shown in FIG. 8 , the transfer pack 18 is constructed such that when the puck inserts 134 are seated in the insert channels 152 of the pack body 130, the puck inserts 134 extend upwardly above the level of the article conveying surface 136 (i.e., upwardly past the side regions 148 and the central region 146 of the article conveying surface 136). The height H that the top wall 166 of each puck insert 134 extends above the article conveying surface 136 can be determined, at least in part, by the compressibility of the puck inserts 134 and how much they compress inwardly when a force is applied. In the exemplary embodiment, that is, the top wall 166 of each puck insert 134 is provided as an inclined member that slopes downwardly from an upper edge 184 disposed adjacent the central region 146 to a lower edge 186 disposed adjacent the longitudinal edge 150 of the pack body 130.

[0077] As previously described with respect to the puck insert 64 of Figures 2-5, the puck insert 134, including the top wall 166, the bottom wall 168, and the pair of side walls 170, is constructed from a compressible, deformable, and / or resilient material that allows the puck insert 134 to be depressed when a force is applied. Thus, according to an embodiment, the puck insert 134 may be constructed from one or more compressible, deformable, or resilient materials, such as, by way of non-limiting example, rubber, silicone rubber, polyurethane, TPA, TPU, TPE, or neoprene foam. The resilient puck insert 134 returns to its original configuration when the compressive force is removed, such as after transfer when the individual items 50 are transferred onto the receiving member 54.

[0078] According to another embodiment, the puck insert 134 may have a solid construction as opposed to the hollow construction shown in Figure 8. In such an embodiment, the puck insert 134 is constructed of a deformable material such as, by way of non-limiting example, rubber, silicone rubber, polyurethane, TPA, TPU, TPE, or neoprene foam. In a solid insert construction, vacuum holes 144 are formed through the full height of the puck insert 134 to communicate vacuum from the vacuum passages 142 in the puck body 130, through the insert 134, and to the article conveying surface 136 of the transfer puck 18.

[0079] As discussed above with respect to the transfer pack 18 shown and described in the embodiment of Figures 2-5 and the embodiment of Figures 6-9, it is recognized that the transfer pack 18 can be configured to include only a single pack insert rather than a pair of pack inserts. Figure 10 illustrates an embodiment of a transfer pack 18 including only a single puck insert 64 therein, which matches that of the embodiment of the puck insert 64 shown and described in Figures 2-5. However, it is recognized that a transfer pack 18 can instead be provided that includes a single puck insert that matches the puck insert 134 of Figures 6-9.

[0080] In the embodiment of FIG. 10, the puck insert 64 is positioned adjacent a leading edge 80a of the transfer pack 18 that will first contact the receiving member 54 as the transfer pack 18 translates to the article placement location 52. As previously discussed (with respect to FIGS. 2-5), the puck insert 64 mates with an insert channel 88 formed in a side region 78 of the article conveying surface 66 along the leading edge 80a of the transfer pack 18. The side region 78 along the opposing trailing edge 80b of the puck body 60 does not include an insert channel 88 (and a mating puck insert 64 therewith), but is instead configured as an extension of the central region 76. That is, the side region 78 along the trailing edge 80b presents a surface extending therefrom at a smooth transition that may slope slightly downwardly from the side adjacent the rim 84 adjacent the edge 80b, with the side region 78 including a plurality of vacuum holes 74 therein.

[0081] 11A-11D, side schematic views of the transfer pack 18 and receiver member 54 during transfer of individual items 50 are provided to better describe and illustrate the interaction of the transfer pack 18 and receiver member 54. As discussed above in the embodiments of Figures 2-5 and 6-9, in the illustrated embodiment, the transfer pack 18 is shown as including a pair of pack inserts 64, 134, however, it will be recognized that the following description is equally applicable to the embodiment of Figure 10 in which the transfer pack 18 includes only a single pack insert disposed adjacent leading edge 80a.

[0082] 11A, the transfer pack 18 moves in a machine direction 55 towards an article placement location 52 where the individual articles 50 are attached to a receiving member 54. At this location, the elastomeric puck inserts 64, 134 are in a resting configuration (i.e., an uncompressed or undepressed state) in which they protrude above the article conveying surface 66 of the transfer pack 18.

[0083] 11B, the leading edge 80a of the transfer pack 18 has reached the item placement location 52 and contacts the receiving member 54 (e.g., web 54 and transfer drum 56) due to interference between the travel path of the transfer pack 18 and the receiving member 54. As the transfer pack 18 contacts the receiving member 54, an applied force is generated between the transfer pack 18 and the receiving member 54 that assists in the transfer of the individual items 50 from the transfer pack 18 to the receiving member 54. This applied force generated causes the puck insert 64, 134 adjacent the leading edge 80a to be depressed inwardly toward the item conveying surface 66 of the transfer pack 18 such that, in one embodiment, the top surface of the puck insert 64, 134 is approximately level with the item conveying surface 66. This depression of the puck insert 64, 134 reduces the forces and stresses imparted to the individual items 50 and the receiving member 54, enabling effective transfer of the individual items 50 to the receiving member 54 while preventing damage that may occur to the individual items 50 during transfer.

[0084] 11C, the leading edge 80a of the transfer pack 18 has rotated past the item placement location 52 such that the puck insert 64, 134 adjacent the leading edge 80a is no longer in contact with the receiving member 54. Additionally, the puck insert 64, 134 adjacent the trailing edge 80b has reached the item placement location 52 and is in contact with the receiving member 54 (e.g., the web 54 and the transfer drum 56) due to interference between the travel path of the transfer pack 18 and the receiving member 54. With the puck insert 64, 134 adjacent the leading edge 80a no longer in contact with the receiving member 54, the puck insert 64, 134 can return or retract to a resting configuration projecting above the item conveying surface 66 (i.e., its uncompressed or undepressed state) since the previously applied force has been removed at this location. Conversely, with the puck insert 64, 134 adjacent the trailing edge 80b now reaching the item placement location 52, the puck insert 64, 134 is in contact with the receiving member 54. As the trailing edge puck insert 64, 134 contacts the receiver member 54, an applied force is generated that presses the puck insert 64, 134 inwardly toward the article conveying surface 66 of the transfer puck 18 so that, in one embodiment, the top surface of the puck insert 64, 134 is approximately level with the article conveying surface 66. This pressing down of the puck insert 64, 134 reduces the forces and stresses imparted to the individual articles 50 and the receiver member 54, allowing for effective transfer of the individual articles 50 to the receiver member 54 while preventing damage that may occur to the individual articles 50 during transfer.

[0085] 11D, the transfer puck 18 has rotated completely past the article placement location 52 such that the leading edge and trailing edge puck inserts 64, 134 are no longer in contact with the receiving member 54. With both puck inserts 64, 134 no longer in contact with the receiving member 54, both puck inserts 64, 134 can return or retract to their resting configuration projecting above the article conveying surface 66 (i.e., their uncompressed or undepressed state) since the previously applied force has been removed at this location.

[0086] It will be appreciated that the transfer packs described above in Figures 2-10 may be implemented in other systems or apparatus other than the cutting and transferring apparatus 10 of Figure 1, according to additional embodiments of the present invention. Such systems or apparatus may include cutting and transferring apparatus configured differently from the apparatus 10 described above, or a turn-and-place apparatus operable to receive a product or component part in a certain orientation, spin (or "rotate") the component part to a desired predetermined angle, and then transfer (or "place") the component part onto another web or receiving member for use in another step of the manufacturing process.

[0087] An example of a turn and place apparatus according to an embodiment is shown in FIG. 12. The turn and place apparatus 190 is configured as a rotating device and includes a plurality of transfer pucks 192 attached to a center hub 194 that rotates about a central axis 196. The apparatus 190 receives individual items 198 at a pick-up point or receiving location 200, such as from a vacuum drum (not shown), where the items 198 are picked up sequentially and individually by the transfer pucks 192. The transfer pucks 192 hold the individual items 198 thereon as they rotate about the central axis 196 on the center plate 194 from the receiving location 200 to the item placement location 202. While moving between the receiving location 200 and the item placement location 202, each of the transfer pucks 192 also spins about its spin axis 204 to reorient the individual items 198 supported thereon. In one embodiment, the individual items 198 can be rotated 90 degrees. After the individual articles 198 are rotated 90 degrees, they are deposited at the article transfer location 202 onto a conveyor 206 that is rotated about a drum 208. The conveyor 206 then transports the individual articles 198 for further processing or to a packaging device, as required by the particular application.

[0088] In yet other embodiments, the transfer packs described above in Figures 2-10 can be utilized in other types of units configured to transfer individual items from a receiving location to an item placement location, such as, for example, a re-pitching unit that picks up individual pieces moving at a first spacing (pitch) and transfers the individual pieces to an item placement location at a larger spacing (pitch) without changing the rotational orientation of the individual pieces. As yet another non-limiting example, the transfer packs described above in Figures 2-10 can be utilized in a device that picks up and deposits individual pieces to change the orientation of the individual pieces without changing the pitch or spacing between the individual pieces.

[0089] In still other embodiments, elastic inserts such as those described above in Figures 2-10 can be utilized in other types of units configured to handle webs or individual articles of material. Such units can include, by way of non-limiting examples, anvils, knife shafts, transfer rolls, No Scrap Ear (NoSE) packs, and waistband sections.

[0090] Advantageously, therefore, embodiments of the present invention provide a transfer pack and overall transfer apparatus that efficiently transfers a wide range of individual components to a receiving surface to accommodate the transfer of individual items of different types and sizes. The transfer pack ensures that the individual components are transferred precisely onto the receiving surface and without damaging the individual components or the receiving surface, even when forces are applied during application and transfer of the individual components.

[0091] Thus, according to one embodiment of the present invention, the apparatus comprises a transfer mechanism configured to transfer a plurality of individual items from an item receiving location to an item placement location, the transfer mechanism comprising a plurality of transfer units moving along a transfer path from the item receiving location to the item placement location, each of the plurality of transfer units comprising a transfer pack selectively operable to carry an individual item thereon as the transfer pack moves between the item receiving location and the item placement location. The apparatus also comprises a receiving member disposed at the item placement location to receive the plurality of individual items from the transfer mechanism. Each transfer pack comprises a pack body having a back surface and an item transport surface having vacuum holes formed therein for holding the individual items thereon via vacuum, the item transport surface comprising a central region and at least one side region adjacent the central region, the at least one side region being aligned longitudinally along the pack body. Each of the transfer packs also comprises a pack insert arrangement including one or more pack inserts disposed around a portion of the circumference of the transfer pack, each of the one or more pack inserts being dimensioned to engage the pack body at a respective side region and to protrude above the item transport surface. Each of the one or more puck inserts is a resilient structure depressible inwardly toward the article-conveying surface upon application of a force.

[0092] According to another embodiment of the invention, there is provided a transfer pack for transferring and placing individual articles onto a receiving surface. The transfer pack comprises a pack body having a back surface and an article conveying surface having vacuum holes formed therein for holding individual articles thereon via vacuum, the article conveying surface comprising a central region and at least one side region adjacent the central region, the at least one side region being aligned longitudinally along the pack body. The transfer pack also comprises a pack insert arrangement including one or more pack inserts disposed about a portion of the periphery of the transfer pack, each of the one or more pack inserts engaging the pack body at a respective side region and projecting above the article conveying surface. Each of the one or more pack inserts is a resilient structure depressible inwardly towards the article conveying surface upon application of force.

[0093] According to yet another embodiment of the invention, there is provided a method of transferring individual items from a transfer pack to a receiving surface. The method includes holding the individual items on an item transport surface of a transfer pack via a vacuum communicating through the transfer pack, the transfer pack comprising one or more puck inserts attached to the item transport surface at one or more side regions thereof so as to be disposed around a portion of a circumference of the transfer pack, each of the one or more puck inserts comprising a resilient structure protruding above the item transport surface and depressible inwardly towards the item transport surface upon application of a force to the item transport surface. The method also includes transferring the individual items from the transfer pack to a receiving surface at an item placement location, the transferring of the individual items comprising contacting the individual items held on the item transport surface to the receiving surface at the item placement location and applying a pressing force from the transfer pack to the receiving surface as the individual items contact the item transport surface to transfer the individual items from the item transport surface to the receiving surface. The pressing force depresses the one or more puck inserts inwardly towards the item transport surface.

[0094] While the present invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the present invention is not limited to such disclosed embodiments. Rather, the present invention can be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the present invention. Moreover, while various embodiments of the present invention have been described, it should be understood that aspects of the present invention may include only some of the described embodiments. Thus, the present invention should not be deemed limited by the foregoing description, but is limited only by the appended claims.

Claims

1. a transport mechanism configured to transport a plurality of individual items from an item receiving location to an item placement location, the transport mechanism comprising a plurality of transport units moving along a transfer path from the item receiving location to the item placement location, each of the plurality of transport units comprising a transport pack selectively operable to carry an individual item thereon as the transport pack moves between the item receiving location and the item placement location; a receiving member disposed at the article placement location to receive the plurality of individual articles from the transfer mechanism; Each of the transfer packs comprises: a pack body comprising a back surface and an article conveying surface having vacuum holes formed therein for holding the individual articles thereon via vacuum, the article conveying surface comprising a central region and at least one side region adjacent the central region, the at least one side region being aligned longitudinally along the pack body; a pack insert arrangement including one or more pack inserts positioned around a portion of the periphery of the transfer pack, each of the one or more pack inserts being dimensioned to engage the pack body at a respective side region and to project above the article conveying surface; The apparatus, wherein each of the one or more puck inserts comprises a resilient structure depressible inwardly toward the article conveying surface upon application of a force.

2. The device of claim 1 , wherein the puck insert arrangement includes a pair of puck inserts.

3. the at least one side region includes a pair of side regions on either side of the central region; 2. The device of claim 1, wherein the puck body includes an insert channel formed in each side region of the pair of side regions, and a puck insert of the one or more puck inserts slidably engages each respective insert channel.

4. 4. The device of claim 3, further comprising an end cap secured to at least one end of the puck body, the end cap closing the insert channel to secure the puck insert within the insert channel.

5. the puck body including one or more vacuum channels formed therein to provide a fluid flow path for a vacuum from the rear surface to the vacuum holes in the article transport surface; 5. The apparatus of claim 1, wherein each of the one or more puck inserts comprises a hollow member defining an internal chamber, the internal chamber being in fluid communication with the vacuum channel of the puck body.

6. each of the one or more pack inserts: a top wall having the vacuum hole formed therein; a bottom wall having one or more openings formed therein; a pair of side walls disposed between the top wall and the bottom wall, separating the top wall from the bottom wall; the top wall, the bottom wall, and the pair of side walls define the interior chamber; 6. The apparatus of claim 5, wherein a vacuum communicates from the vacuum channel in the puck body, through the opening in the bottom wall, and through the interior chamber to the vacuum hole in the top wall.

7. 7. The apparatus of claim 6, wherein each of the one or more puck inserts comprises a trapezoidal shaped member with the pair of side walls being parallel.

8. 7. The device of claim 6, wherein for each of the one or more pack inserts, the top wall slopes from an upper edge located adjacent the central region to a lower edge located adjacent a longitudinal edge of the pack body.

9. 7. The device of claim 6, wherein each of the one or more puck inserts comprises a bellows-shaped member that flexes inwardly and depresses upon application of force.

10. 5. The apparatus of any one of claims 1 to 4, wherein each of the one or more pack inserts is constructed from rubber, silicone rubber, polyurethane, thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or neoprene foam.

11. The device of any one of claims 1 to 4, wherein the transfer mechanism is configured to force each of the plurality of transfer units into contact with the receiving member at the item placement location to transfer the plurality of individual items onto the receiving member, and the forced contact presses the elastic structure inward toward the item conveying surface.

12. An apparatus according to any preceding claim, wherein the pack insert arrangement comprises a single pack insert located at a leading edge of the transfer pack that initially contacts the receiving member at the item placement location.

13. 1. A transfer pack for transferring and placing discrete items onto a receiving surface, comprising: a pack body comprising a back surface and an article conveying surface having vacuum holes formed therein for holding the individual articles thereon via vacuum, the article conveying surface comprising a central region and at least one side region adjacent the central region, the at least one side region being aligned longitudinally along the pack body; a pack insert arrangement comprising one or more pack inserts disposed around a portion of the periphery of the transfer pack, each of the one or more pack inserts engaging the pack body at a respective side region and projecting above the article conveying surface; A transfer pack, wherein each of the one or more pack inserts comprises a resilient structure depressible inwardly toward the article conveying surface upon application of a force.

14. the at least one side region includes a pair of side regions disposed on either side of the central region; 14. The transfer pack of claim 13, wherein the pack body includes an insert channel formed in each respective side region of the pair of side regions, and each pack insert of the one or more pack inserts slidably engages with a respective insert channel.

15. 15. The transfer pack of claim 14, wherein the pack insert configuration includes a pair of pack inserts, each pack insert of the pair engaging a respective insert channel.

16. the puck body including one or more vacuum channels formed therein to provide a fluid flow path for a vacuum from the rear surface to the vacuum holes in the article transport surface; 16. A transfer pack according to any one of claims 13 to 15, wherein each of the one or more pack inserts comprises a hollow member defining an internal chamber, the internal chamber being in fluid communication with the vacuum channel of the pack body.

17. each of the one or more pack inserts: a top wall having the vacuum hole formed therein; a bottom wall having one or more openings formed therein; a pair of side walls disposed between the top wall and the bottom wall, separating the top wall from the bottom wall; the top wall, the bottom wall, and the pair of side walls define the interior chamber; 17. The transfer pack of claim 16, wherein a vacuum communicates from the vacuum channel in the pack body, through the opening in the bottom wall, and through the interior chamber to the vacuum hole in the top wall.

18. 18. The transfer pack of claim 17, wherein for each of the one or more pack inserts, the upper wall slopes from an upper edge located adjacent the central region to a lower edge located adjacent a longitudinal edge of the pack body.

19. The transfer pack of any one of claims 13 to 15, wherein the one or more pack inserts each comprise a bellows-shaped member that flexes inwardly and depresses upon application of force.

20. The transfer pack of any one of claims 13 to 15, wherein the central region includes a recessed region, and the side regions and each of the one or more pack inserts protrude above the recessed region.

21. 1. A method for transferring discrete items from a transfer pack to a receiving surface, comprising: holding individual articles on an article conveying surface of the transfer pack via a vacuum communicated through the transfer pack, the transfer pack comprising one or more pack inserts attached to the article conveying surface at one or more side regions thereof so as to be disposed around a portion of the periphery of the transfer pack, each of the one or more pack inserts projecting above the article conveying surface and comprising a resilient structure depressible inwardly towards the article conveying surface upon application of a force; transferring the individual items from the transfer pack onto the receiving surface of an item placement location; The step of transferring the individual items comprises: bringing the individual items held on the item conveying surface into contact with the receiving surface at the item placement location; applying a pressing force from the transfer pack to the receiving surface when the individual object contacts the object conveying surface, thereby transferring the individual object from the object conveying surface to the receiving surface; the pressing force pressing the one or more puck inserts inwardly toward the article conveying surface.

22. 22. The method of claim 21, wherein the pressing force depresses a pack insert of the one or more pack inserts located at a front edge of the transfer pack that first contacts the receiving surface at the item placement location.

23. 23. The method of claim 22, wherein the pressing force depresses a pack insert of the one or more pack inserts located at a trailing edge of the transfer pack opposite the leading edge.

24. 24. A method according to any one of claims 21 to 23, wherein the vacuum communicated through the transfer pack is communicated through vacuum holes formed in the article conveying surface and the one or more pack inserts.

Images