Patent Application
20160001900
The present disclosure is directed to a rigid dispenser for dispensing a granular material from a replaceable and disposable cartridge contained therein. More particularly, the present disclosure teaches a rigid canister for sanitarily dispensing sugar and powdered creamer prepackaged within a replaceable and disposable cartridge and method and apparatus for the production of the replaceable and disposable cartridge.
Dry powder dispensing canisters for office or general public use, e.g., office sugar canisters, are typically made of cardboard cylinders with a cardboard or metal base and a plastic or metal cap, often with product trade dress features on the outer cylindrical portion of the canister. Such products are considered throwaway products, in that once the contents are used and the canister is empty, the canister is thrown away and ultimately added to a land-fill. Other dry powder condiment personal use dispensers are made of glass or plastic and require frequent cleaning and refilling, i.e., such as a glass diner sugar canister or glass salt and pepper shaker. The first solution creates a throwaway item, is relatively costly and is not environment friendly. The second solution requires the processing of a bulk product by the user and requires relatively frequent cleaning and refilling. Hence, solutions for eliminating the waste and expense of prior dispensers while providing the convenience and sanitation of a replaceable and disposable dispenser would be advantageous.
According to one aspect of the present disclosure is a dispenser for dispensing a dry, pourable material, the dispenser comprise a canister body having a closed end, an open end and a cavity of a predetermined volume and shape. The canister body having a replaceable and disposable cartridge prefilled with a predetermined quantity of the dry, pourable material received within the cavity, the replaceable and disposable cartridge having a predetermined volume and shape corresponding to the that of the canister body, the replaceable and disposable cartridge including a dispensing end sealed with flexible membrane, where the entire replaceable and disposable cartridge, including the flexible membrane, is fabricated from a biodegradable material. A pouring spout cap is attached proximate the open end of the canister body, the pouring spout cap movable between an open position and closed position, wherein the pouring spout cap sealingly engages the open end of the canister body and encloses the replaceable and disposable cartridge within the cavity when the pouring spout cap is in the closed position, the pouring spout cap further comprising an upper surface defining a first lower portion of a dispensing chamber and a spout. A pierce pin forming a conduit in communication with the dispensing chamber and the replaceable and disposable cartridge depending from the lower surface of the pouring spout cap and disposed to pierce the flexible membrane of the replaceable and disposable cartridge when the pouring spout cap is in the closed position. A cap lid is attached to the upper surface of the pouring spout cap, the cap lid defining a second upper portion of the dispensing chamber, wherein the first lower portion of the dispensing chamber and the second upper portion of the dispensing chamber define the dispensing chamber from which the dry, pourable material is dispensed from the replaceable and disposable cartridge through the pierce pin and the dispensing chamber, and out of the dispensing chamber through the spout for dispensing the dry, pourable material from the dispenser.
Another aspect of the present disclosure is a dispenser, wherein the flexible membrane is a formed from a continuous membrane.
Still another aspect of the present disclosure is a dispenser, wherein the flexible membrane is fabricated from cellulose acetate.
A further aspect of the present disclosure is a dispenser, comprising a spring loaded lock having a locked position and a released position for retaining the pouring spout cap in the closed position and releasing the pouring cap spout when the lock is in the released position.
Yet another aspect of the present disclosure is a dispenser, further comprising a ridge on the spout pouring cap, the lock further having a notch engaging the ridge when the lock is in the locked position and the pouring cap spout is in the closed position to restrain the pouring cap spout in the closed position.
Still another aspect of the present disclosure is a dispenser, further comprising a resilient spring mounted on an outer wall of the canister body proximate a first portion of the lock and the notch formed on a second portion of the lock, wherein the lock is pivotably mounted between the first portion and the second portion to the outer wall of the canister body proximate the open end of the canister body.
A further aspect of the present disclosure is a dispenser, further comprising an opening in the outer wall of the canister body within which the resilient spring is mounted.
Yet a further aspect of the present disclosure is a dispenser, further comprising a ring topper mounted about the open end of the canister body, the ring topper having a first hinge member and the pouring spout cop having a second hinge member rotatably coupled with the first hinge member for rotating the pouring spout cap between the open position and the closed position.
Still another aspect of the present disclosure is a dispenser, further comprising a door hingedly attached to an upper portion of the cap lid attached to the upper surface of the pouring spout cap proximate the spout, the door rotating between a closed position when the dispenser is upright and an open position when the dispenser is tilted relative a horizontal ground for dispensing the dry, pourable material from the dispenser.
An additional aspect of the present disclosure is a dispenser, further comprising a cap liner attached to and substantially covering the lower surface of the pouring spout cap, the cap liner having an opening through which the pierce pin depends and disposed to otherwise seal the cavity of the canister body when the pourable spout cap is in the closed position.
A yet additional aspect of the present disclosure is a dispenser, wherein the lower surface of the pouring spout cap further comprises a depending lip forming an opening within which the pierce pin is attached and through which the pierce pin depends.
A further aspect of the present disclosure is a dispenser, wherein the lower surface of the pouring spout cap further comprises a recess into which an anchor extending upwardly from the cap liner is received to attach the cap liner to the pouring spout cap.
An additional aspect of the present disclosure is a dispenser, wherein the replaceable and disposable cartridge is a tube having a first and a second sealed end, and wherein at least the first sealed end comprises an open rim on the tube and the flexible membrane disposed over and around the open rim, the flexible membrane having an exposed surface and a surface adjacent to and in contact with the open rim.
Yet another aspect of the present disclosure is a dispenser, wherein the flexible membrane is sealingly attached to the open rim of the tube by an adhesive disposed on the surface adjacent to and in contact with the open rim.
A further aspect of the present disclosure is a dispenser, wherein the open rim has a first diameter and the flexible membrane has a central portion having a second diameter, the second diameter exceeding the first diameter, and a plurality of radially extending legs extending outwardly from the central portion and along a longitudinal axis of the replaceable and disposable cartridge when disposed over and around the open rim.
Still another aspect of the present disclosure is a dispenser, wherein the flexible membrane has twelve radially extending legs.
According to another aspect of the present disclosure, a dispenser for dispensing a dry, pourable material, the dispenser comprises a canister body having a closed end, an open end and a cavity. The dispenser having a replaceable and disposable cartridge prefilled with a predetermined quantity of the dry, pourable material received within the cavity, the replaceable and disposable cartridge fabricated from a biodegradable material and having a dispensing end sealed with a flexible membrane, the flexible membrane having a central portion sealing the dispensing end of the replaceable and disposable cartridge and plurality of radially extending legs extending outwardly from the central portion and along a longitudinal axis of the replaceable and disposable cartridge, a pouring spout cap attached to the canister body, the pouring spout cap movable between an open position and closed position, wherein the pouring spout cap sealingly engages the open end of the canister body and encloses the replaceable and disposable cartridge within the cavity when the pouring spout cap is in the closed position, the pouring spout cap further comprising an upper surface defining a first lower portion of a dispensing chamber and a spout; a pierce pin forming a conduit in communication with the dispensing chamber and the replaceable and disposable cartridge depending from a lower surface of the pouring spout cap and disposed to pierce the flexible membrane of the replaceable and disposable cartridge when the pouring spout cap is in the closed position; and a cap lid attached to the upper surface of the pouring spout cap, the cap lid defining a second upper portion of the dispensing chamber, wherein the first lower portion of the dispensing chamber and the second upper portion of the dispensing chamber define the dispensing chamber from which the dry, pourable material is dispensed from the replaceable and disposable cartridge, through the pierce pin, into the dispensing chamber and out of the dispensing chamber through the spout for dispensing the dry, pourable material from the dispenser.
A further aspect of the present disclosure is a replaceable and disposable cartridge for use in a dispenser for dispensing a dry, pourable material, the dispenser comprising a canister body, a pouring spout cap attached to an open end of the canister body, the pouring spout cap movable between an open position and a closed position, wherein the pouring spout cap sealingly engages the open end of the canister body when the pouring spout cap is in the closed position, a pouring spout, and a pierce pin depending from a lower surface of the pouring spout cap in communication with the pouring spout, the replaceable and disposable cartridge comprising: a tube adapted for insertion within a cavity in the canister body having an interior and a first sealed end comprising an opening at a first end of the tube and a flexible membrane disposed over and around the opening to seal the opening, wherein the flexible membrane is pierced by the pierce pin when the pouring spout cap is moved to the closed position to provide communication between the interior of the tube and the pouring spout, wherein both the tube and the flexible membrane are fabricated from a biodegradable material; and a predetermined quantity of the dry, pourable material prefilled into the tube for dispensing from the interior of the tube, through the piecing pin and out of the dispenser through the pouring spout.
A yet further aspect of the present disclosure is a replaceable and disposable cartridge, wherein the flexible membrane is fabricated from cellulose acetate.
A still yet further aspect of the present disclosure is a replaceable and disposable cartridge, wherein the flexible membrane has an exposed surface and a surface adjacent to the opening, and wherein the flexible membrane is sealingly attached to the opening of the tube by an adhesive disposed on the surface adjacent to the opening.
According to another aspect of the present disclosure is a replaceable and disposable cartridge, wherein the tube further comprises a second sealed end, the second sealed end comprising an opening at the second end of the tube and a flexible membrane disposed over and around the second opening to seal the second opening.
A further aspect of the present disclosure is a replaceable and disposable cartridge, wherein the canister body has a cavity of a predetermined volume and shape and the replaceable and disposable cartridge has a predetermined volume and shape corresponding to the volume and shape of the canister body and is received within the cavity.
A yet further aspect of the present disclosure is a replaceable and disposable cartridge, wherein the pouring spout cap encloses the replaceable and disposable cartridge within the cavity when the pouring spout cap is in the closed position.
Still another aspect of the present disclosure is a replaceable and disposable cartridge, wherein the pouring spout cap further comprises an upper surface defining a first lower portion of a dispensing chamber and a spout, a cap lid attached to the upper surface of the pouring spout cap defining a second upper portion of the dispensing chamber, wherein the first lower portion of the dispensing chamber and the second upper portion of the dispensing chamber define the dispensing chamber from which the dry, pourable material is dispensed from the replaceable and disposable cartridge, through the pierce pin into the dispensing chamber, and out of the dispensing chamber through the spout for dispensing the dry, pourable material from the dispenser.
According to another aspect of the present disclosure is a method for producing a replaceable and disposable cartridge for use in a dispenser for dispensing a dry, pourable material, the dispenser comprising a canister body, a pouring spout cap attached to an open end of the canister body, the pouring spout cap movable between an open position and a closed position, wherein the pouring spout cap sealingly engages the open end of the canister body when the pouring spout cap is in the closed position, a pouring spout, and a pierce pin depending from a lower surface of the pouring spout cap in communication with the pouring spout, the method comprising: forming a tube adapted for insertion within a cavity in the canister body, the tube having an interior and a first end and a second end, wherein each end comprises an opening; sealing the first opening; filling the second end of the tube with a predetermined quantity of the dry, pourable material; and disposing a flexible membrane over and around the second opening to seal the second opening, wherein the flexible membrane is pierced by the pierce pin when the pouring spout cap is moved to the closed position to provide communication between the interior of the tube and the pouring spout, and wherein both the tube and the flexible membrane are fabricated from a biodegradable material.
A still further aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, further comprising the step of inverting the tube between the step of sealing the first opening and the step of filling the second end of the tube.
A yet further aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the flexible member is disposed on a feed tape having a first layer comprising the flexible member and a second layer comprising a peelable backing paper, wherein a first surface of the flexible membrane is coated with an adhesive in removable contact with the second layer.
Another aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the first layer of the feed tape is perforated into a plurality of flexible membranes having a starburst shape comprising a plurality of radially extending legs.
An additional aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the second layer has a split seam along either side of the feed tape to form a central portion and two side edges of the second layer of the feed tape, wherein the method further comprises the step of peeling the central portion of the second layer of the feed tape to expose the adhesive coated on the first surface of the flexible membrane prior to disposing the flexible membrane over and around the second opening to seal the second opening.
A yet further aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the starburst shape comprises twelve radially extending legs.
A still further aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the flexible membrane is formed from a cellulose acetate membrane
Another aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, further comprising the step of moving a punch collar comprising an upper disk, an intermediate disk, and a lower disk over the second opening to form and affix the flexible membrane about the second opening to seal the second opening.
Yet another aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the first layer of the feed tape is perforated into a plurality of flexible membranes having a starburst shape comprising a plurality of radially extending legs.
Still yet another aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the lower disk of the punch collar has a lower face comprising a plurality of downwardly depending and inclined fingers, each finger corresponding to a leg of the flexible membrane.
Yet a further aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein an inner diameter of the intermediate disk of the punch collar is provided with a plurality of corresponding raised steps, each step corresponding to a leg of the flexible membrane and a finger of the lower face of the lower disk.
Still a further aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the upper disk is provided with an inner diameter which, when brought about the tube of the replaceable and disposable cartridge, urges the flexible membrane into contact with an outer surface of the tube.
Yet another aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the feed tape is indexed to bring one of the plurality of flexible membranes into registration with second opening to seal the second opening.
A still further aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the peelable backing paper is removed by a take-off roller prior to disposing the flexible membrane over and around the second opening to seal the second opening.
A further aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein a punch collar is forced downwardly over and around the second opening of the tube after the flexible membrane is disposed over the second opening to seal the second opening.
Yet a further aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the flexible member has a plurality of outwardly extending legs and a lower face of the punch collar has a corresponding plurality of downwardly extending fingers that engage the outwardly extending legs of the flexible membrane and brings the legs of the flexible membrane into close proximity with an outer wall of the tube.
Still yet a further aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein an inner diameter of the punch collar has a plurality of raised steps that correspond with the plurality of legs of the flexible membrane that further push the legs of the flexible membrane into contact with the outer wall of the tube.
An additional aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the inner diameter of the punch collar further presses the plurality of legs of the flexible membrane into contact with the outer wall of the tube.
A further aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the punch collar further comprises a vent intermediate an upper and a lower surface of the punch collar to allow the escape of air to provide flat and smooth application of the legs of the flexible membrane to the sidewalls of the tube.
A still further aspect of the present disclosure is a method for producing a replaceable and disposable cartridge, wherein the punch collar is retracted upwardly for positioning above a second tube and the next flexible membrane of the plurality of sealing membranes.
According to another aspect of the present disclosure is a method for producing a replaceable and disposable cartridge for use in a dispenser for dispensing a dry, pourable material, the dispenser comprising a canister body, a pouring spout cap attached to an open end of the canister body, the pouring spout cap movable between an open position and a closed position, wherein the pouring spout cap sealingly engages the open end of the canister body when the pouring spout cap is in the closed position, a pouring spout, and a pierce pin depending from a lower surface of the pouring spout cap in communication with the pouring spout, the method comprising: forming a first of a series of tubes adapted for insertion within a cavity in the canister body, the first tube having an interior and a first end and a second end, wherein each end comprises an opening; transporting the first tube to a first sealing station; disposing a first flexible membrane over and around the first opening to seal the first opening of the first tube; transporting the first tube to a filling station; filling the second end of the first tube with a predetermined quantity of the dry, pourable material; transporting the first tube to a second station; and disposing a second flexible membrane over and around the second opening of the first tube to seal the second opening, wherein one of either the first flexible membrane or the second flexible membrane is pierced by the pierce pin when the pouring spout cap is moved to the closed position to provide communication between the interior of the tube and the pouring spout, and wherein both the tube and the flexible membrane are fabricated from a biodegradable material.
Still another aspect of the present disclosure is an apparatus for the production of a replaceable and disposable cartridge fabricated from a biodegradable material for use in a dispenser for dispensing a dry, pourable material, the dispenser comprising a canister body, a pouring spout cap attached to an open end of the canister body, the pouring spout cap movable between an open position and a closed position, wherein the pouring spout cap sealingly engages the open end of the canister body when the pouring spout cap is in the closed position, a pouring spout, and a pierce pin depending from a lower surface of the pouring spout cap in communication with the pouring spout, the apparatus comprising: a roller for dispensing a feed tape having a first layer comprising a flexible member and a second layer comprising a peelable backing paper, wherein a first surface of the flexible membrane is coated with an adhesive in removable contact with the second layer, the first layer of the feed tape is perforated into a plurality of flexible membranes and the second layer has a split seam along either side of the feed tape to form a central portion and two side edges of the second layer of the feed tape; a take-off roll for peeling away the central portion of the second layer of the feed tape to expose the adhesive coated on the first surface of the flexible membrane prior to disposing the flexible membrane over and around the second opening to seal the second opening; a sealing station comprising a base portion which receives a tube having an open upper end in a fixed position and an upper head further comprising a punch collar attached to a platen vertically displaceable in an upwardly and downwardly direction to affix the flexible membrane over and around the second opening to seal the second opening; and a take-up roller for rolling up the feed tape after the flexible membrane has been affixed over and around the second opening to seal the second opening
A further aspect of the present disclosure is an apparatus for the production of a replaceable and disposable cartridge, wherein the platen is displaced by actuation of an air cylinder.
A still further aspect of the present disclosure is an apparatus for the production of a replaceable and disposable cartridge, wherein the first layer of the feed tape is perforated into a plurality of flexible membranes having a starburst shape comprising a plurality of radially extending legs.
Yet another aspect of the present disclosure is an apparatus for the production of a replaceable and disposable cartridge, wherein the starburst shape comprises twelve radially extending legs.
Still another aspect of the present disclosure is an apparatus for the production of a replaceable and disposable cartridge, wherein the flexible membrane is formed from a cellulose acetate membrane.
An additional aspect of the present disclosure is an apparatus for the production of a replaceable and disposable cartridge, wherein the punch collar further comprises an upper disk, an intermediate disk, and a lower disk over the second opening to form the flexible membrane about the second opening to seal the second opening,
Yet another aspect of the present disclosure is an apparatus for the production of a replaceable and disposable cartridge, wherein a lower surface of the punch collar has a plurality of downwardly depending and inclined fingers, each finger corresponding to a leg of the flexible membrane.
Still another aspect of the present disclosure is an apparatus for the production of a replaceable and disposable cartridge, wherein an inner diameter of the punch collar is provided with a plurality of corresponding raised steps, each step corresponding to a leg of the flexible membrane and a finger of the lower surface of the lower disk.
Yet another aspect of the present disclosure is an apparatus for the production of a replaceable and disposable cartridge, wherein a portion of the inner diameter of the punch collar, when brought about the tube, urges the flexible membrane into contact with an outer surface of the tube.
A still further aspect of the present disclosure is an apparatus for the production of a replaceable and disposable cartridge, wherein a vent is provided intermediate the lower surface and an upper surface of the punch collar to allow air to escape and to promote the flat and smooth application of the legs of the flexible membrane to the sidewalls of the tube.
These and other aspects, objects, and features of the present disclosure will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
Referring to the drawings,
Attached to the bottom surface 28 of the pouring spout cap 20 is a cap liner 30, preferably comprised of a sanoprene, semi-soft seal material that effectively covers the bottom surface 28 of the pouring spout cap 20. The pouring spout cap 20 is provided with a lower portion 32 of a dispensing chamber 34 which is in fluid communication with an opening 36 having a lower lip 38, about which an opening 40 in the cap liner 30 is disposed, in order to provide a sealing arrangement. The cap liner 30 also provides a seal around the outer periphery of the pouring spout cap 20 as it sits within the ring topper 18 and engages the upper lip 93 of the canister body 14. A pierce pin 42 is disposed within the opening 36 in the pouring spout cap 20 and has an outer diameter 44 which corresponds to an inner diameter 46 of the opening 36 for a tight fit and is glued in place with an adhesive. The pouring spout cap 20 is preferably fabricated from ABS plastic as well. The pierce pin 42, however, is preferably fabricated from a hard plastic, such as polycarbonate plastic, and is rigid in its construction. The pierce pin 42 can be of the same material and formed as part of or separate to the pouring spout cap 20. Where the pierce pin 42 is a separate component, multiple material selections and pierce pin geometry are available. The pierce pin 42 can also be fabricated from stainless steel to ensure a sanitary component.
A cap lid 48 having an upper portion 50 of the dispensing chamber 34 is fixed, preferably via an adhesive, to an upper sloped surface 52 of the pouring spout cap 20, as shown in
An opposite side 82 of the ring topper 18 is provided with an outwardly extending pair of opposing ears 84 within which a lock 86 is received. The lock 86 is preferably attached via an 0.030″×0.75″ stainless steel dowel pin 88 to allow limited rotation of the lock 86 within the ears 84. A spring 90 is positioned within an opening 92 disposed just below the outwardly extending ears 84 on the upper portion 26 of the canister body 14, where the spring 90 is preferably manufactured from a soft silicon, such as sanoprene, and has an abutting portion 94 and a mounting plug 96. The mounting plug 96 is preferably provided within an enlarged end 98. The mounting plug 96 has an outer diameter 100 that closely matches an inner diameter 102 of the opening 92 in the upper portion 26 of the canister body 14. The mounting plug 96 of the spring 90 is inserted into the opening 92, whereby the enlarged end 98 of the mounting plug 96 is compressed during assembly and is released upon final assembly to restrain the spring 90 within the opening 92.
On a forward portion 104 of the pouring spout cap 20 is a outwardly extending ridge or locking tab 106 which extends horizontally. An upper portion 108 of the lock 86 is provided with a corresponding notch 110 that, likewise, extends horizontally. As the pouring spout cap 20 is moved to the closed position, the ridge 106, which is provided with a slight incline on either side, is brought into engagement with the notch 110 on the upper portion 108 of the lock 86. The spring 90, however, urging against a lower portion 112 of the lock 86, pushes the notch 110 on the lock 86 into engagement with the ridge 106 to secure the pouring spout cap 20 in place upon the canister body 14.
As shown in
As shown in
The replaceable and disposable cartridge 58, shown in
In order to dispense the dry, powdered material 56 within the replaceable and disposable cartridge 58, the canister 14 is simply inclined to allow the dry, powdered material 56 inside the replaceable and disposable cartridge 58 to flow through the resulting opening 134 in the flexible membrane 124, through the pierce pin 42, and through the dispensing chamber 34 created by the upper portion 50 of the pouring spout cap 20 and the lower portion 32 of the cap lid 48. From there, the dry, powdered material 56 flows through the spout 54 and under the door 60 into the item desired, such as, for example, granulated sugar poured into a cup of coffee. When returned to the upright position, the door 60 on the cap lid 48 swings to the closed position, thereby preventing debris and other contaminants from entering into the canister body 14 and preserving and safeguarding the dry, powdered material 56 within the replaceable and disposable cartridge 58 for further sanitary use.
The combination of the cap lid 48 and the pouring spout cap 20, as shown in
As a further feature of the present disclosure, the replaceable and disposable cartridge is manufactured with the unique flexible membrane 124 and method of installing the flexible membrane 124. Whereas prior art systems required a plug to be installed on cardboard tubes for sealing the upper and lower end, the same typically required the plug to be pressed into place in a wet configuration, where heat subsequently was applied to cause the plug to adhere to the tubular container. This resulted in a significant consumption of energy.
The replaceable and disposable cartridge 58 according to the present disclosure is assembled in four essential steps. The first step is that the first end 130 of the tube 128 is sealed with a flexible membrane 124, the second step is where the tube 128 is inverted, the third step is where the tube 128 is then filled with the dry, powdered material 58, and fourth, the second end of the tube 128 is then sealed with a second flexible membrane 124.
Preferably, the flexible membrane 124 is formed into a starburst shape 140 having twelve legs 142, as best shown in FIGS. 17 and 25-27. The legs 142 of the starburst pattern of the flexible membrane 124 are also preferably provided with a small radius 144 at the apex 146 of their intersection. That is, at the base 148 of each of the legs 142, a small radius 144 of approximately preferably about 0.030″ is provided to provide relief to the leg 142 as it ultimately comes into substantially vertical relationship with its adjacent leg 142 in the installed position. It has been found that the failure to provide such a radius 144 results in splits or tears at the intersection of the legs 142, which if close to the ends 130, 132 of the tube 128, can result in loss of seal along the longitudinal axis of the cartridge 58.
The cellulose acetate flexible membrane 124 covering the tube end 130, 132 can be colored, translucent, or opaque. Preferably, it is colored in order to protect the contents from light. However, a translucent material allows for the ready inspection of the contents of the replaceable and disposable cartridge 58 so that it may be apparent to the user what dry, powdered material 56 is being inserted into the canister body 14.
An outer circular periphery 150 of the center portion 152 of the flexible membrane 124, excluding the legs, is preferably about 3.125″. The outer diameter 154, including the legs 142, is roughly 4.635″. Thus, each of the legs 142 is preferably approximately 0.5″ as it extends outwardly.
The flexible membrane 124 is preferably formed from a feed tape 156 obtained from the 3M Company, specially perforated and prepared in accordance with the present disclosure. As specified by the present disclosure, the feed tape 156 has two separate layers: a first upper layer 158 manufactured out of cellulose acetate, and a second lower layer 160 is a backing paper that allows the handling of the cellulose acetate membrane 124. A lower surface 162 of the cellulose acetate first upper layer 158 is provided with a thin layer of clear adhesive 164 that is retained by the backing paper 160. The upper layer 158 of the feed tape 156 is first perforated into a plurality of flexible membranes 124 in the form of a series of starburst shapes 140, as shown in
The assembly of the replaceable and disposable cartridge is accomplished through the apparatus 186 shown in
The sealing station 180 is uniquely provided with a punch collar 194, shown in situ within the head section 193 in
In operation, the tube 128, which has been provided with a seal on the lower surface, which is preferably, but not necessarily, the flexible membrane 124, is inverted and then filled with a predetermined amount of dry, powdered material 56. The tube 128 is then transported to the sealing station 180 for sealing the second open end 132 of the replaceable and disposable cartridge 58. However, as described herein, the manner of closing either end 130, 132 of the replaceable and disposable cartridge 58 and enclosing it with the flexible membrane 124 is preferably the same. The tube 128 is thus brought into the sealing station 180, wherein the indexed feed tape 156 bearing the flexible membrane 124 is brought into alignment with the open first end 130 of the tube 128. Just prior to entering the sealing station 180, the take-off roller 184 removes the central portion 174 of the backing paper 160 on the feed tape 156 to expose the adhesive 164 on the flexible membrane 124. Thus, when the flexible membrane 124 is brought into alignment with the open end 130 of the tube 128, there is no backing paper 160 to interfere with the flexible membrane 124 being affixed to the tube 128.
The punch collar 194 is then forced downwardly over and around the open end 130 of the tube 128. The downwardly extending fingers 210 of the lower disk 200 of the punch collar 194 thus engage the outwardly extending legs 142 of the flexible membrane 124, pushes the edges of the flexible membrane 124 to break it along the perforations from the first upper layer 158, and brings them into close proximity with the outer wall 220 of the tube 128. The raised steps 212 of the intermediate disk 198 of the punch collar 194 further push the legs 142 of the flexible membrane 124 into contact with the outer wall 220 of the tube 128. Finally, the close proximity and the tight fit of the inner diameter 218 of the upper disk 196 further presses the flexible membrane 124 into contact with the outer wall 220 of the tube 128. The adhesive 164 on the exposed lower surface 162 of the flexible membrane 124 thus causes the flexible membrane 124 to affix itself to the outer wall 220 of the tube 128 without the need for heat or further processing. The punch collar 194 is then retracted upwardly for positioning of the next tube 128 and registration of the next flexible membrane 124, per the indexed feed of the feed tape 156 for the flexible membranes 124 into the sealing station 180. The completely formed and filled replaceable and disposable cartridge 58 is ready for packaging and shipment to the ultimate end user in accordance with the disclosure.
A particularly advantageous feature of the present disclosure is that the resulting replaceable and disposable cartridge 58 can be filled with any granular material desired to be dispensed, such as granulated sugar or powdered creamers, and can then be replaced whenever the replaceable and disposable cartridge 58 within the canister 12 is depleted. The discarded cartridge 58, owing to its fabrication from recyclable and biodegradable components, thus poses no concerns with regard to waste and/or landfill. The canister 12, which as noted above, is constructed from rugged and durable plastics, can be re-used a virtually infinite number of times before needing to be replaced. An especially desirable aspect of the canister 12 is that it can be affixed with logos and various trade dress features, such as color, print, or graphics, to provide an aesthetic benefit without having to continually reapply such trade dress elements to products which are presently being used for dispensing such granular materials and which are ultimately discarded.
As described above, the replaceable and disposable cartridge 58 and canister assembly 12 disclosed, as well as the machinery and methods for manufacturing the replaceable and disposable cartridge 58, provide a much faster and efficient method of assembling a sealed cartridge 58 for a reusable canister 12. In addition, less energy is consumed by virtue of the simple need for compressed air to run a pneumatic actuator 206 to bring the punch collar 194 into and out of engagement with the outer wall 220 of the upper end 130 of the cartridge 58 to affix the flexible membrane 124 to the replaceable and disposable cartridge 58 and thereby antiseptically close the end 130.
The canister 12 which houses the cartridge 58 can be of any shape, e.g., circular, square, rectangular, or hexagonal, so long as it matches the shape of the replaceable and disposable cartridge 58. Each can be attached to the pour spout cap 20 as previously described. Materials suited for the canister 12 containing the replaceable and disposable cartridge 58 include plastic, aluminium, stainless steel, plastics, or other materials. That is, while the canister 12 has been described as made from hard, rigid, durable plastic materials, glass or stainless steel may be used as desired. The canister 12 may also be provided with a silicon rubber skin (not shown) for better grasp.
As described herein, a dry powder dispenser 10 has a replaceable and disposable cartridge 58 allows 100% recycling and/or biodegradable disposal of the spent cartridge 58. The canister 12 has a pouring spout cap 20 that allows the use of the cost effective and environmentally friendly replaceable and disposable dry powder cartridge 58. The replaceable and disposable cartridge 58 is fully contained by an outer shell 12 and pouring spout cap 20, ensuring containment of product. Once the cap 20 is closed and pierces the cartridge 58, the dry, powdered material 56 inside the replaceable and disposable cartridge 58 may be poured out by tilting the canister 12. When the material 56 inside the replaceable and disposable cartridge 58 is emptied, the replaceable and disposable cartridge 58 can be removed and replaced with a full cartridge 58. The canister 12 with the pouring spout cap 20 is re-used. The replaceable and disposable cartridge 58 can be of any geometrical volume and is shaped to conform to the inner volume of and fitted to the canister 12 in order to cooperate with the pierce pin 42 on the pouring spout cap 20.
This design may also be adapted for use applications for dispensing non-food related dry products, i.e., medical, automotive, or sport powders, where contamination and disposal of the cartridge is of relevant concern.
It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
