Carton singulation unit
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2026-02-05
- Publication Date
- 2026-08-13
Smart Images
Figure IB2026051087_13082026_PF_FP_ABST
Abstract
Description
[0001] CARTON SINGULATION UNIT
[0002] FIELD OF THE INVENTION
[0003]
[0001] The present invention generally relates to a carton singulation unit, more particularly, it relates to a unit which separates out or isolates a carton blank from a stack of carton blanks in packaging industry.
[0004] BACKGROUND OF THE INVENTION
[0005]
[0002] In a wide range of industries, from manufacturing and packaging to logistics and office environments, it is a frequent necessity to handle stacks of articles such as packaging sheets, blanks, and other thin, flat materials. These articles or blanks are typically stored in stacks, in a nested configuration, for efficient handling and transportation. For example, in order to supply empty containers like boxes, templates of the boxes are made by attaching requisite sides of respective blanks. These templates are then stacked in the nested configuration and supplied to the manufacturer. This configuration allows minimizing space taken up by the empty containers during transportation and storage phase. Once at the manufacturer’s site, the templates are folded-out, typically by a machine, and empty boxes are formed.
[0006]
[0003] However, these blanks when stacked tend to stick together due to friction, static electricity, or other factors, making it difficult to efficiently separate and handle individual pieces. Thin and lightweight blanks can be particularly prone to sticking together, which leads to difficulties in manual separation and increases the chances of misfeeds or jams when mechanical systems are employed. For instance, in automated systems like printers or packaging lines, failure to properly separate blanks can lead to costly downtime, waste of materials, and loss of productivity. Manual methods for separation are also labor-intensive and susceptible to human error, further complicating high-throughput operations.
[0004] Various solutions have been proposed and implemented in the past to address these issues, each with its own set of drawbacks. Mechanical separation systems, such as those involving rollers, claws, springs, or blades, physically separate the blanks but often at the cost of damaging the blanks. These mechanical systems also require constant calibration and maintenance to account for variations in blank thickness, texture, and material composition, limiting their flexibility.
[0007]
[0005] Pneumatic systems that use air jets or vacuum- based mechanisms to separate blanks from a stack offer another approach. However, these systems face their own challenges. Air-based systems can be inconsistent when dealing with materials of different weights, porosities, or sizes, often leading to irregular handling or misfeeds. Additionally, pneumatic systems can be less effective in environments where dust or other contaminants affect air pressure control, leading to operational inefficiencies.
[0008]
[0006] A further challenge with current methods is their limited adaptability across different types of blanks. In many industrial settings, the types, sizes, and thicknesses of the blanks being handled can vary widely. Most existing separation systems are specialized and optimized for specific materials or formats, meaning that they are not easily adaptable to handle a diverse range of blanks without significant modifications or downtime for recalibration. This inability leads to bottlenecks in automation, particularly in industries like printing, packaging, and material handling.
[0009]
[0007] Thus, there is a need in the art for a carton singulation unit which addresses at least the aforementioned problems.SUMMARY OF THE INVENTION
[0010]
[0008] The present invention discloses a carton singulation unit for separating blank from a stack of blanks. The unit has a blank dispenser configured to dispense a blank from the stack of blanks for a pick-up arm to pick up a blank dispensed from the stack of blanks. The unit further has a blank isolator disposed at an end of the blank dispenser and configured to separate the blank from the stack of blanks, having: a locking plate; and a pressure plate, the locking plate and the pressure plate configured to operate in an alternative linear motion by a cam assembly driven by a driving mechanism, such that a single rotation of the cam assembly causes the locking plate to release and thereby separate one blank from the stack of blanks while remaining stack of blanks is held in position by the pressure plate.
[0011]
[0009] In an embodiment of the invention, the blank dispenser has a top plate extending from a proximal end to a distal end; and a bottom plate disposed parallel to the top plate and extending from a proximal end to a distal end, whereby the stack of blanks is disposed between the top plate and the bottom plate, the blank dispenser configured to facilitate a gravitational movement in the stack of blanks.
[0012]
[0010] In another embodiment, the distal end of the bottom plate has a recess which receives the separated blank from the remaining stack of blanks thereby isolating the separated blank.
[0013] [Oil] In yet another embodiment of the invention, the top plate and the bottom plate are angularly bent at the distal ends, such that the stack of blanks moves gravitationally.
[0014]
[0012] In a further embodiment, the blank isolator is disposed at the distal end of the top plate of the blank dispenser.
[0015]
[0013] In an embodiment of the invention, the locking plate is mechanically biased. Further, the locking plate has a lip extending vertically downwards, whereby in a biased position the lip onthe locking plate impedes movement of the stack of blanks, and in an unbiased position the lip on the locking plate releases the stack of blanks. In another embodiment, the lip of the locking plate is substantially perpendicular to the top plate of the blank dispenser.
[0016]
[0014] In yet another embodiment, the pressure plate is mechanically biased and is disposed adjacent to the locking plate, whereby in a biased position the pressure plate applies mechanical pressure on the stack of blanks and impedes the movement of the stack of blanks, and in an unbiased position the pressure plate releases the pressure on the stack of blanks effecting the movement of the stack of blanks.
[0017]
[0015] In another embodiment, the cam assembly has a first cam operatively coupled to the locking plate, whereby the first cam has a groove on one side. In another embodiment, the locking plate has a projection on an upper surface.
[0018]
[0016] In a further embodiment, the groove on the first cam receives the projection on the upper surface of the locking plate thereby unbiasing the locking plate.
[0019]
[0017] In another embodiment of the invention, the cam assembly has a second cam operatively coupled to the pressure plate, whereby the second cam has a nose on one side. In a further embodiment, the groove of the first cam is aligned with the nose of the second cam.
[0020]
[0018] In another embodiment of the invention, the driving mechanism includes a servo motor, or a DC motor.
[0021] BRIEF DESCRIPTION OF THE DRAWINGS
[0022]
[0019] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles. Reference has been made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures constitute a part of thisdisclosure are intended to be illustrative, and together with the description, serve to explain the invention. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
[0023] Figure 1 shows the carton singulation unit in accordance with an embodiment of the invention.
[0024] Figure 2 shows a blank isolator in accordance with an embodiment of the invention. Figure 3 a shows a locking plate of the blank isolator in accordance with an embodiment of the invention.
[0025] Figure 3b shows a pressure plate of the blank isolator in accordance with an embodiment of the invention.
[0026] Figure 4 shows the carton singulation unit in a biased position in accordance with an embodiment of the invention.
[0027] DETAILED DESCRIPTION OF THE INVENTION
[0028]
[0020] Embodiments of the present disclosure, disclose an carton singulation unit. The terms “comprises”, “comprising”, or any other variations thereof used in the specification, are intended to cover a non-exclusive inclusion, such that a mechanism and method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such mechanism or method.
[0029]
[0021] For the purposes of promoting an understanding of the principles of the disclosure, reference will be made to specific embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of thescope of the disclosure is thereby intended, such alterations and further modifications in the illustrated methods, and such further applications of the principles of the disclosure as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention pertains.
[0030]
[0022] The present invention relates to a carton singulation unit 300. Referring to Figure 1, the carton singulation unit 300 has a blank dispenser 200 which is configured to dispense a blank from a stack of blanks X. As seen in the Figure, the dispensed / separated blank is then meant for a pick-up arm 400 to be picked up from the stack of blanks X. Referring to Figures 1 and 2, in an embodiment of the invention, the blank dispenser 200 has a top plate 210 which extends from a proximal end 210a to a distal end 201b. In the same embodiment, the blank dispenser 200 has a bottom plate 220 disposed parallel to the top plate 210 as seen in Figure 1. The bottom plate 220 also extends from a proximal end 220a (not shown) to a distal end 220b. As seen in Figures 1 and 4, the top plate 210 and the bottom plate 220 of the blank dispenser 200 run parallel to each other, whereby the stack of blanks X is disposed between the top plate 210 and the bottom plate 220. In an embodiment of the invention, the blank dispenser 200 is configured to facilitate gravitational movement in the stack of blanks X. In this embodiment, referring to Figure 2, top plate 210 and the bottom plate 220 (not shown in Figure 2) are angularly bent at their distal ends 210b, 220b. This angular bent there by causes the stack of blanks X to move gravitationally towards the pick-up arm 400.
[0031]
[0023] Referring to Figure 2, the carton singulation unit 300 of the present invention has a blank isolator 100. The blank isolator 100 is disposed at an end of the blank dispenser 200 and is configured to separate the blank from the stack of blanks X. In an embodiment of the invention, and as seen in Figure 2, the blank isolator 100 is disposed at the distal end 210b of the top plate210 of the blank dispenser. According to the invention, the blank isolator 100 has a locking plate 110 and a pressure plate 120.
[0032]
[0024] In an embodiment of the invention, both, the locking plate 110 is mechanically biased. Referring to Figure 3 a, in an embodiment, the locking plate 110 is mechanically biased by at least one spring actuated mechanism 118. As seen in the Figure, in the embodiment of the invention, the locking plate 110 is mechanically biased by two spring actuated mechanisms 118. In the same embodiment, each of spring actuated mechanism 118 has a compression spring 116 disposed inside a guide 117. Thus, as seen in Figures 1 and 4, in a biased position, the locking plate 110 is moved downwards. Whereas, in an unbiased position, the locking plate 110 is moved upwards. Referring yet to Figures 1, 2 and 4, in an embodiment of the invention, the locking plate 110 has a lip 112 which extends vertically downwards. In a further embodiment, the lip 112 of the locking plate 110 is substantially perpendicular to the top plate 210 of the blank dispenser 200. As seen in Figures 1 and 4 of the same embodiment, in a biased position the lip 112 on the locking plate 110 impedes movement of the gravitationally moving stack of blanks X, whereas in an unbiased position the lip 112 on the locking plate 110 releases the gravitationally moving stack of blanks X. Referring to Figure 3 a, in another embodiment of the invention, the locking plate 110 has projection 114 on an upper surface 110a.
[0033]
[0025] In an embodiment of the invention, and as seen in Figure 2, the pressure plate 120 is disposed adjacent to the locking plate 110 and is mechanically biased as well. Referring to Figure 3b, in an embodiment, the pressure plate 120 is mechanically biased by at least one spring actuated mechanism 128. As seen in the Figure, in the embodiment of the invention, the pressure plate 120 is mechanically biased by two spring actuated mechanisms 128. In the same embodiment, each of spring actuated mechanism 128 has a compression spring 126 disposedinside a guide 127. Thus, as seen in Figures 1 and 4, in a biased position, the pressure plate 120 is moved downwards, whereas, in an unbiased position, the pressure plate 120 is moved upwards. According to the invention, in the biased position, the pressure plate 120 exerts a predetermined non-deforming mechanical force on the gravitationally moving stack of blanks X thereby impeding their movement, whereas in an unbiased position the pressure plate 120 releases the pressure on the stack of blanks X thereby allowing the gravitational movement of the stack of blanks X.
[0034]
[0026] According to the invention, the locking plate 110 and the pressure plate 120 are configured to operate in an alternative linear motion by a cam assembly 130 driven by a diving mechanism 140. Referring to Figures 2, 3a and 3b, the cam assembly 130 has a first cam 132 which is operatively connected to the locking plate 110. Referring to Figure 3a, in an embodiment, the first cam 132 has a groove 132’ on one side of the first cam 132. The groove 132’ of the first cam 132 is shaped to receive the projection 114 of the locking plate 110. Thus, when the cam assembly 130 is made to rotate and the projection 114 of the locking plate 110 is received inside the grove 132’ of the first cam 132, the locking plate 110 is brought in an unbiased position, i.e. away from the stack of blanks X. Further, as the locking plate 110 is unbiased so is the lip 112, thereby causing the lip 112 to also move away from the stack of blanks X. This leads to the release of the gravitationally moving stack of blanks X.
[0035]
[0027] Referring yet to Figures 2, 3a and 3b, the cam assembly 130 has a second cam 134 which is operatively connected to the pressure plate 120. Referring to Figure 3b, in an embodiment, the second cam 134 has a nose 134’ on one side of the second cam 134. Thus, when the cam assembly 130 is made to rotate and the nose 134’ of the second cam 134 interacts with the pressure plate 120, the pressure plate 120 is brought in a biased position, i.e. towards the stack ofblanks X. This biasing of the pressure plate 120 by the nose 134’ of the second cam 134 causes the pressure plate 120 to exert the predetermined non-deforming mechanical force on the gravitationally moving stack of blanks X thereby impeding their movement. Whereas when the nose 134’ of the second cam 134 moves away from the pressure plate 120, the pressure plate 120 comes in an unbiased position thereby releasing the pressure on the stack of blanks X and allowing the gravitational movement of the stack of blanks X. In an embodiment of the invention, the groove 132’ of the first cam 132 is aligned with the nose 134’ of the second cam 134.
[0036]
[0028] As mentioned hereinabove, the cam assembly 130 is driven by a driving mechanism 140. As seen in Figure 2, in an embodiment of the invention, the driving mechanism 140 is coupled to the cam assembly 130 through the camshaft 146. In another embodiment, the driving mechanism may be a servo motor, or a DC motor, or any device which may bring about a controlled rotation of the cam shaft 146 and consequently the cam assembly 130.
[0037]
[0029] According to the invention, a single rotation of the cam assembly 130 causes the locking plate 110 to release and thereby separate one blank from the stack of blanks X while remaining of the stack of blanks X-l (not shown) is held in position by the pressure plate 120. Referring to Figure 1, in an embodiment of the invention the bottom plate 220 of the blank dispenser 200 has a recess R. The recess R further receives the separated blank from the remaining stack of blanks (X-l) thereby isolating the separated blank.
[0038]
[0030] In operation, when the driving mechanism 140 is actuated, the camshaft 146 in turn gets rotated. The rotation of the camshaft 146 consequently causes the cam assembly 130 to rotate.
[0039] AS explained hereinabove, the groove 132’ of the first cam 132 is in line with the nose 134’ of the second cam 134. Referring to Figure 4, during initiation of the rotation of the cam shaft 146,when the respective dwells of the first cam 132 and the second cam 134 interact with the locking plate 110 and the pressure plate 120, the locking plate 110 is in a biased position while the pressure plate 120 is in an unbiased position in view of the configurations explained hereinabove. Thus, the gravitational movement of the stack of blanks X is held in position owing to the lip 112 of the locking plate 110. At this point there the pressure plate 120 does not exert any pressure on the stack of blanks X.
[0040]
[0031] Referring now to Figure 1, during the rotation of the cam shaft 146, when the groove 132’ of the first cam 132 interacts with the projection of 114 of the locking plate 110, the locking plate 110 is unbiased and moves upwards due to project! on- groove interaction. This causes the lip 112 of the locking plate 110 to move upwards, i.e away from the stack of blanks X. Simultaneously during this rotation, the nose 134’ of the second cam 134 interacts with the pressure plate 120 causing the pressure plate 120 to come in a biased position. Resultantly, a first blank among the stack of blanks X becomes free of impedance. Simultaneously, and as seen in Figure 1, since the pressure plate 120 is in a biased position, the pressure plate 120 exerts the pressure on the remaining stack of blanks X-l, which is consequently held in position. Further, the first blank then shifts into the recess R present at a distal end 220b of the bottom plate 220 of the blank dispenser 200. This slight step-down of the first blank makes the blank to be available and therefore be picked up by a rotating pick-up arm 400 for further process.
[0041]
[0032] Further, as soon as the cam shaft 146 rotates the first cam 132 and the second cam 134 onto their respective dwells, pressure caused by the pressure plate 120 on the remaining stack of blanks (X-l) is removed and the remaining stack of blanks (X-l) move downwards, which are impeded by the lip 112 of the locking plate 110 which is also back in the biased position.
[0033] Advantageously, the carton singulation unit of the present invention offers a range of significant advantages, addressing the longstanding challenges associated with reliably singling out individual blanks from a stack. First and foremost, the unit ensures consistent and precise separation of the blanks. This allows the unit to handle a wide variety of blanks, without requiring complex adjustments or specialized configurations. The unti minimizes damage to delicate or sensitive packaging materials, making it ideal for industries that prioritize material integrity. Unlike traditional mechanical methods that risk tearing or scratching blanks, the unit employs optimized and controlled mechanical mechanisms, which enhance reliability while preserving the quality of the blanks. Another key advantage is the reduction of operational inefficiencies. The unit eliminates common issues such as misfeeds, jams, or double-feeding, which are prevalent in conventional separation methods. This leads to higher throughput and less downtime, translating to increased productivity and cost savings. Additionally, the unit’s adaptability reduces the need for frequent recalibrations, making it a time-efficient solution for processes involving variable blank types or conditions.
[0042]
[0034] While various aspects and embodiments have been disclosed hereinabove, other aspects and embodiments will be apparent to those skilled in the art. However, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention.
Claims
We Claim:
1. A carton singulation unit (300) for separating a carton blank from a stack of blanks (X), comprising:a blank dispenser (200) configured to dispense a blank from the stack of blanks (X) for a pick-up arm (400) to pick up a blank dispensed from the stack of blanks (X); and a blank isolator (100) disposed at an end of the blank dispenser (200) and configured to separate the blank from the stack of blanks (X), comprising: a locking plate (110); and a pressure plate (120), the locking plate (110) and the pressure plate (120) configured to operate in an alternative linear motion by a cam assembly (130) driven by a driving mechanism (140), such that a single rotation of the cam assembly (130) causes the locking plate (110) to release and thereby separate one blank from the stack of blanks (X) while remaining stack of blanks (X-l) is held in position by the pressure plate (120).
2. The carton singulation unit (300) as claimed in claim 1, wherein the blank dispenser (200) comprises: a top plate (210) extending from a proximal end (210a) to a distal end (210b); and a bottom plate (220) disposed parallel to the top plate (210) and extending from a proximal end (220a) to a distal end (220b), whereby the stack of blanks (X) is disposed between the top plate (210) and the bottom plate (220), the blank dispenser (200) configured to facilitate a gravitational movement in the stack of blanks (X).
3. The carton singulation unit (300) as claimed in claim 2, wherein the distal end (220b) of the bottom plate (220) comprises a recess (R) which receives the separated blank from the remaining stack of blanks (X-l) thereby isolating the separated blank.
4. The carton singulation unit (300) as claimed in claim 2, wherein the top plate (210) and the bottom plate (220) are angularly bent at the distal ends (210b, 220b), such that the stack of blanks (X) moves gravitationally.
5. The carton singulation unit (300) as claimed in claims 1 and 4, wherein the blank isolator (100) is disposed at the distal end (210b) of the top plate (210) of the blank dispenser (200).
6. The carton singulation unit (300) as claimed in claim 1, wherein the locking plate (110) is mechanically biased.
7. The carton singulation unit (300) as claimed in claim 1, wherein the locking plate (110) comprises a lip (112) extending vertically downwards, whereby in a biased position the lip (112) on locking plate (110) impedes movement of the stack of blanks (X), and in an unbiased position the lip (112) on locking plate (110) releases the stack of blanks (X).
8. The carton singulation unit (300) as claimed in claims 2 and 7 and, wherein the lip (112) of the locking plate (110) is substantially perpendicular to the top plate (210) of the blank dispenser (200).
9. The carton singulation unit (100) as claimed in claim 1, wherein the pressure plate (120) is mechanically biased and is disposed adjacent to the locking plate (110), whereby in abiased position the pressure plate (120) applies mechanical pressure on the stack of blanks (X) and impedes the movement of the stack of blanks (X), and in an unbiased position the pressure plate (120) releases the pressure on the stack of blanks (X) effecting the movement of the stack of blanks (X).
10. The carton singulation unit (300) as claimed in claim 1, wherein the cam assembly (130) comprises a first cam (132) operatively coupled to the locking plate (110), whereby the first cam (132) comprises a groove (132’) on one side.
11. The carton singulation unit (300) as claimed in claim 1, wherein the locking plate (110) comprises a projection (114) on an upper surface (110a).
12. The carton singulation unit (300) as claimed in claim 10, wherein the groove (132’) on the first cam (132) receives the projection (114) on the upper surface (110a) of the locking plate (110) thereby unbiasing the locking plate (110).
13. The carton singulation unit (300) as claimed in claim 1, wherein the cam assembly (130) comprises a second cam (134) operatively coupled to the pressure plate (120), whereby the second cam (134) comprises a nose (134’) on one side.
14. The carton singulation unit (100) as claimed in claims 10 and 13, wherein the groove15. The carton singulation unit (100) as claimed in claim 1, wherein the driving mechanism (140) includes a servo motor, or a DC motor.