Singulating conveyor system

1. A singulating conveyor designed to accept a continuous, randomly arranged collection of packages and sort the packages into a single file, lengthwise oriented fashion comprising:

a plurality of conveyor sets with each conveyor set comprising a left group and a right group;

the left group comprising an outer attachment means, an inner attachment means, a plurality of tapered rollers attached to the outer attachment means and inner attachment means in such a fashion so as to allow the plurality of tapered rollers to rotate and so that the top edge of each roller creates a horizontal plane;

the plurality of tapered rollers of the left group are assembled in a herringbone pattern such that the angle alpha (“α”) between the left group inner attachment means and the tapered roller is 90° or less in the direction of flow of the singulating conveyor;

the rotation of tapered rollers of the left group is controlled by a drive means;

the right group comprises an outer attachment means, an inner attachment means, a plurality of tapered rollers attached to the outer attachment means and inner attachment means in such a fashion so as to allow the plurality of tapered rollers to rotate and so that the top edge of each roller creates a horizontal plane;

the plurality of tapered rollers of the right group are assembled in a herringbone pattern such that the angle (“β”) between the right group inner attachment means and the tapered roller is 90° or less in the direction of flow of the singulating conveyor;

the rotation of tapered rollers of the right group is controlled by a drive means;

the inner attachment means of the left group is positioned against the inner attachment means of the right group to create the centerline of the conveyor set;

the tapered rollers in the first conveyor set of the plurality of conveyor sets are oriented such that each tapered roller is tapered from the outer attachment means toward the inner attachment means so that, because of the difference in speed of rotation along each tapered roller and the herringbone layout of the tapered rollers, as packages enter the first conveyor set each package is re-oriented so that the longest length of the package aligns with the flow direction of the singulating conveyor, each package is adjusted to move along the conveyor set centerline and those packages closer to the outer attachment means of the singulating conveyor move faster and ahead of those packages located closer to the centerline; and

wherein the plurality of tapered rollers in any of the subsequent conveyor sets are oriented so that each tapered roller tapers from the centerline toward the outer attachment means such that, if an outside package is adjacent to a package traveling along the centerline, the package traveling along the centerline moves faster than the outside package and the outside package would fall in behind the package traveling along the centerline.

2. The singulating conveyor of claim 1 where the plurality of tapered rollers of a subsequent set are oriented so that each tapered roller tapers from the outer attachment means toward the centerline such that, if an outside package is adjacent to a package traveling along the centerline, the package traveling along the centerline moves slower than the outside package and the outside package would move ahead of the package traveling along the centerline.

3. The singulating conveyor of claim 2 wherein the plurality of tapered rollers in any of the subsequent conveyor sets are oriented so that each tapered roller tapers from the centerline toward the outer attachment means such that, if an outside package is adjacent to a package traveling along the centerline, the package traveling along the centerline moves faster than the outside package and the outside package would fall in behind the package traveling along the centerline.

4. A singulating conveyor designed to accept a continuous, randomly arranged collection of packages and sort the packages into a single file, lengthwise oriented fashion comprising:

plurality of conveyor sets with each conveyor set comprising a left group and a right group;

the left group comprising an outer attachment means, an inner attachment means, a plurality of tapered rollers attached to the outer attachment means and inner attachment means in such a fashion so as to allow the plurality of tapered rollers to rotate and so that the top edge of each roller creates a horizontal plane;

the plurality of tapered rollers of the left group are assembled in a herringbone pattern such that the angle alpha (“α”) between the left group inner attachment means and the tapered roller is 90° or less in the direction of flow of the singulating conveyor;

the rotation of tapered rollers of the left group is controlled by a drive means;

the right group comprises an outer attachment means, an inner attachment means, a plurality of tapered rollers attached to the outer attachment means and inner attachment means in such a fashion so as to allow the plurality of tapered rollers to rotate and so that the top edge of each roller creates a horizontal plane;

the plurality of tapered rollers of the right group are assembled in a herringbone pattern such that the angle (“β”) between the right group inner attachment means and the tapered roller is 90° or less in the direction of flow of the singulating conveyor;

the rotation of tapered rollers of the right group is controlled by a drive means;

the inner attachment means of the left group is positioned against the inner attachment means of the right group to create the centerline of the conveyor set;

the tapered rollers in the first conveyor set of the plurality of conveyor sets are oriented such that each tapered roller is tapered from the inner attachment means toward the outer attachment means so that, because of the difference in speed of rotation along each tapered roller and the herringbone layout of the tapered rollers, as packages enter the first conveyor set each package is re-oriented so that the longest length of the package aligns with the flow direction of the singulating conveyor, each package is adjusted to move along the conveyor set centerline and those packages closer to the centerline of the singulating conveyor move faster and ahead of those packages located closer to the outer attachment means; and

wherein the plurality of tapered rollers in any of the subsequent conveyor sets are oriented so that each tapered roller tapers from the outer attachment means toward the centerline such that, if an outside package is adjacent to a package traveling along the centerline, the package traveling along the centerline moves slower than the outside package and the outside package would move ahead of the package traveling along the centerline.

5. The singulating conveyor of claim 4 where the plurality of tapered rollers in any of the subsequent conveyor sets are oriented so that each tapered roller tapers from the centerline toward the outer attachment means such that, if an outside package is adjacent to a package traveling along the centerline, the package traveling along the centerline moves faster than the outside package and the outside package would fall in behind the package traveling along the centerline.

6. The singulating conveyor of claim 5 where the plurality of tapered rollers in any of the subsequent conveyor sets are oriented so that each tapered roller tapers from the outer attachment means toward the centerline such that, if an outside package is adjacent to a package traveling along the centerline, the package traveling along the centerline moves slower than the outside package and the outside package would move ahead of the package traveling along the centerline.