Automated Systems and Methods for Combining Cards and Products

Abstract

According to various aspects, exemplary embodiments are disclosed of an automated system for combining cards and products for packaging. Also disclosed are exemplary automated methods for combining cards and products for packaging. In an exemplary embodiment, an automated system for combining cards and products generally includes a card station and a merge station. The card station is configured to form a card to a desired shape for combining with a product. The card station includes at least one roll former operable to fold at least a portion of the card. The merge station is configured to receive the formed card from the card station and combine the formed card with the package.

What is claimed is: 
     
         1 . An automated system for combining cards and products for packaging, the system comprising:
 a card station configured to form a card to a desired shape for combining with a product, the card station having at least one roll former operable to fold at least a portion of the card; and   a merge station configured to receive the formed card from the card station and combine the formed card with the product.   
     
     
         2 . The system of  claim 1 , further comprising a guide configured to position the formed card in a desired orientation for combining with the product. 
     
     
         3 . The system of  claim 1 , wherein the merge station includes a stop configured to position the formed card in the merge station and combine the formed card with the product. 
     
     
         4 . The system of  claim 1 , further comprising a glue applicator configured to apply glue to a portion of the card for coupling the card to the product. 
     
     
         5 . The system of  claim 4 , further comprising a guide configured to position the formed card in an orientation for combining with the product, such that the glue contacts at least part of the product when the card is combined with the product. 
     
     
         6 . The system of  claim 5 , further comprising a press configured to contact the card when combining the card with the product to thereby contact the glue with the at least part of the package. 
     
     
         7 . The system of  claim 1 , wherein the card station includes a card feeder and a conveyor, the conveyor operable to move the card from the card feeder to the at least one roll former, and move the formed card from the at least one roll former to the merge station. 
     
     
         8 . The system of  claim 7 , wherein the conveyor includes at least one lug configured to contact the card and move the card from the card feeder to the at least one roll former and from the at least one roll former to the merge station. 
     
     
         9 . The system of  claim 8 , wherein the at least one lug includes first and second lugs configured to contact the card and move the card, the first lug having a different height than the second lug. 
     
     
         10 . The system of  claim 1 , further comprising a feed station configured to isolate the product from multiple products, and transport the isolated product to the merge station. 
     
     
         11 . The system of  claim 10 , wherein the feed station includes a feed conveyor configured to transport the isolated product to the merge station. 
     
     
         12 . The system of  claim 10 , wherein the feed station includes a simulation unit having a stop and a sensing device for isolating the product from the multiple products. 
     
     
         13 . The system of  claim 1 , further comprising a packaging station configured to receive a combined card and product and shrink wrap the combined card and product. 
     
     
         14 . The system of  claim 1 , wherein the at least one roll former includes a first roll former operable to form a first portion of the card, and a second roll former operable to form a second portion of the card. 
     
     
         15 . An automated method of combining a card and a product for packaging, the method comprising:
 applying glue to a portion of a card at a card station for use in coupling the card to a product;   forming the card at the card station to a desired shape, based on a shape of the product;   conveying the formed card to a merge station;   conveying the product to the merge station;   positioning the formed card in a desired orientation in the merge station to receive the product; and   pressing the glue to a surface of the product, to thereby combine the card and the product.   
     
     
         16 . The method of  claim 15 , further comprising conveying the combined card and product to a packaging station. 
     
     
         17 . An automated system for combining cards and products for packaging, the system comprising:
 a card station configured to form a card to a desired shape for combining with a product, the card station having a first roll former operable to fold a first portion of the card and a second roll former operable to fold a second portion of the card, to thereby form the card to a desired shape, and a guide configured to position the formed card in a desired orientation for combining with the product;   a merge station configured to receive the formed card from the card station and combine the formed card with the package; and   a feed station configured to isolate the product from multiple products, and transport the isolated product to the merge station.   
     
     
         18 . The system of  claim 17 , wherein the card station further includes a glue applicator configured to apply glue to a portion of the card for coupling the card to the product; and wherein the merge station includes a press configured to contact the card when combining the card with the product to thereby contact the glue with the at least part of the package. 
     
     
         19 . The system of  claim 18 , wherein the card station further includes further comprising a guide configured to position the formed card in an orientation for combining with the product, such that the glue contacts at least part of the product when the card is combined with the product. 
     
     
         20 . The system of  claim 17 , wherein the first roll former includes a first series of rollers and a second series of rollers, and wherein the second series of rollers gradually change in orientation to thereby fold the first portion of the card.