Information
-
Patent Grant
-
6205746
-
Patent Number
6,205,746
-
Date Filed
Thursday, January 28, 199925 years ago
-
Date Issued
Tuesday, March 27, 200123 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
-
CPC
-
US Classifications
Field of Search
US
- 053 410
- 053 412
- 053 1331
- 053 1332
- 053 1333
- 053 1334
- 493 87
- 493 929
- 493 213
- 493 214
-
International Classifications
-
Abstract
A post processing fitment applicator for applying a fitment to a formed, filled and sealed carton is disclosed herein. The post processing fitment applicator may be utilized in conjunction with a linear form, fill and seal packaging machine such as a TETRA REX® packaging machine. The post processing fitment applicator includes a supply of fitments, a plurality of fitment carriers, a conveyor system and a hot melt dispenser. The plurality of fitment carriers are disposed on a continuous track that partially parallels the movement of a series of formed, filled and sealed cartons on the conveyor system. The plurality of fitment carriers is capable of applying a fitment to a formed, filled and sealed carton as it is moving along the conveyor system. Each of the plurality of fitment carriers may include a fitment holder and a fitment displacement mechanism.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fitment or closure applicator. More specifically, the present invention relates to a post processing fitment applicator for formed, filled and sealed gable top cartons.
2. Description of the Related Art
Gable top cartons have long been the preferred package for milk and milk related products. Recently, gable top cartons have assumed a new role as the preferred package for juices, particularly orange juice. The consumers preference for gable top cartons is at least partially generated by the perception of freshness associated with the gable top carton. The opposing top panels meeting to form the gable top with a top fin creates an image of a fresh, healthy product contained within the carton. The only detraction from this image was the lack of a tight reseal of the carton after the initial opening of the carton by a consumer. The integrated closure formed from the side of the top of the carton allowed for good pourability, however, the resealing was adequate at best.
This minor detraction was alleviated with the introduction of plastic fitments applied to the gable top cartons. The fitments, which generally include a spout with a flange and a cap, allowed for a tight reseal of the carton after the initial opening. The use of fitments on cartons further enhanced the consumer's perception that gable top cartons contained fresh and healthy products.
In the rush to meet the consumer's demand, the packaging industry developed new packaging/filling machines that applied a fitment to cartons prior to sterilization or filling. The demand to have packaging machines with the smallest “footprint” (the area of the machine) in a dairy meant that most older machines did not have sufficient space within the machine to incorporate a fitment applicator. This rendered older machines without the ability to provide a carton with a fitment thereby reducing their value to the dairy or like facility. Thus a need to apply a fitment on a formed, filled and sealed carton grew throughout the packaging industry.
Another problem necessitating the need to apply a fitment on a formed, filled and sealed carton pertains to maintaining a sterile environment within a form, fill and seal packaging machine to produce an extended shelf life (“ESL”) product, a high acid ambient distribution (“HAAD”) product, or an aseptic product. The ESL product allows for a product to have double or triple the refrigerated shelf life of a non-ESL product. The HAAD product allows for a high acid (pH<4.5) product such as orange juice to be stored unrefrigerated for an extended time period. The aseptic product allows for any product to be stored unrefrigerated for an extended time period. All of these products need to be produced in a sterile, contaminant-free environment.
Current in-line fitment applicators generate substantial amounts of possible contaminants such as dust, paper particles and fitment particles. Ultrasonic fitment applicators generate the greatest amount of contaminants due to the enormous sealing pressures utilized during application of the fitment to the carton. Other applicators such as hot melt fitment applicators may introduce undesirable chemicals, and also may provide inadequate seals. Although the use of induction heat sealing avoids some of the potential problems of in-line applicators, such induction heat sealing applicators necessitate the use of a carton with an aluminum barrier layer which increases the cost of the package. Further, the deliver of fitments from a supply of fitments introduces contaminants into the packaging machine environment.
Some post processing fitment applicators are currently available from the packaging industry. However, these applicators are little more than stand-alone reproductions of current in-line fitment applicators. Such applicators are not the denouement of post processing fitment applicators from the packaging industry.
BRIEF SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide a post processing fitment applicator to apply a fitment to a formed, filled and sealed carton.
It is an additional object of the present invention to provide a post processing fitment applicator that is capable of properly orienting a fitment for placement on a carton.
It is an additional object of the present invention to provide a post processing fitment applicator that is capable of applying a fitment to a moving formed, filled and sealed carton.
One aspect of the present invention is a post processing fitment applicator for applying fitments to each of a series of formed, filled and sealed cartons. The applicator includes a conveyor, a continuous track, a plurality of fitment carriers, a chute and a hot melt dispenser. The conveyor transports the series of formed, filled and sealed cartons through the applicator. The continuous track is partially positioned in proximity to the conveyor. Each of the plurality of fitment carriers is moveable about the continuous track for placing a fitment on a formed, filled and sealed carton. The chute delivers fitments from a supply of fitments to each of the plurality of fitment carriers at a receiving point along the continuous track. The hot melt dispenser is disposed subsequent to the receiving point along the continuous track and coats each of the fitments on each of the plurality of fitment carriers with hot melt.
Each of the plurality of fitment carriers of the post processing fitment applicator may include a fitment holder for holding a fitment and a fitment displacement mechanism for placing the fitment on a formed, filled and sealed carton. The supply of fitments of the post processing fitment applicator may include a hopper connected to the chute, a holding bin, and an elevator disposed to transport fitments from the bin to the hopper. The conveyor system may transport a set number of cartons at predetermined intervals for application of fitments to the cartons. The post processing fitment applicator may also include a housing encompassing at least the continuous track and the hot melt dispenser. Each of the plurality of fitment carriers of the post processing fitment applicator may be moveable toward and away from the cartons being conveyed on the conveyor system. The fitment displacement mechanisms of the post processing fitment applicator may include an U-shaped frame with a projection thereon for engagement with a fitment.
Another aspect of the present invention is a method for applying a fitment to a formed, filled and sealed carton. The first step of the method includes placing a fitment in a fitment carrier being moved along a continuous track. The next step includes rendering the fitment in an adhesive state. The next step includes conveying the formed, filled and sealed carton along a conveyor system disposed in relation to a portion of the continuous track. The final step includes applying the fitment in the adhesive state to the carton as the carton is conveyed along the conveyor system.
The method may also include centering the formed, filled and sealed carton by a plurality of projections on the fitment carrier before applying the fitment. The rendering step of the method may include dispensing hot melt to the back of the fitment. The rendering step of the method may alternatively include heating the back of the fitment to a temperature greater than the melting temperature of the fitment. The fitment applying step of the method may include engaging the back of the fitment to a pre-scored area of the formed, filled and sealed carton while the fitment is within the fitment holder, and displacing the fitment from the fitment holder by actuation of the fitment displacement mechanism. The method may also include orienting the fitment prior to placement of the fitment on the fitment carrier.
Yet another aspect of the present invention is a post processing fitment applicator that includes means for transporting cartons, a plurality of fitment carriers, means for moving each of the fitment carriers, a chute and means for rendering the back of the fitment in an adhesive state. Each fitment carrier places a fitment on a formed, filled and sealed carton. The moving means moves each of the plurality of fitment carriers at a movement equal to that of the transporting means for the series of formed, filled and sealed cartons. The chute delivers fitments from a supply of fitments to each of the plurality of fitment carriers at a receiving point. The rendering means renders the back of the fitment in an adhesive state.
Each of the plurality of fitment carriers of this embodiment of the applicator may include a fitment holder for holding a fitment and a fitment displacement mechanism for placing the fitment on a formed, filled and sealed carton. The supply of fitments of this embodiment of the applicator may include a hopper connected to the chute, a holding bin, and an elevator disposed to transport fitments from the bin to the hopper. The rendering means of this embodiment of the applicator may include means for heating the back of the fitment with hot air to a melting temperature of the fitment. The applicator of this embodiment may include a housing. The applicator of this embodiment may also include means for moving each of the cartons toward and away from the cartons being transported by the transport means. The rendering means of the applicator of this embodiment may include means for inducing a current in the back of the fitment to heat the back of the fitment to a melting temperature of the fitment.
Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
There is illustrated in
FIG. 1
a schematic perspective view of the post processing fitment applicator of the present invention.
There is illustrated in
FIG. 2
a top perspective view of the post processing fitment applicator of the present invention.
There is illustrated in
FIG. 3
an isolated view of a fitment carrier of the plurality of carriers of the post processing fitment applicator of the present invention.
There is illustrated in
FIG. 4
an isolated view of the plurality of fitment carriers of the post processing fitment applicator of the present invention applying fitments to cartons.
There is illustrated in
FIG. 5
a reverse view of the plurality of fitment carriers of FIG.
4
.
There is illustrated in
FIG. 6
a top perspective view of a carton with a fitment thereon applied by the post processing fitment applicator of the present invention.
There is illustrated in
FIG. 7
a top plan view of the carton of FIG.
6
.
There is illustrated in
FIG. 8
a side view of the carton of FIG.
6
.
There is illustrated in
FIG. 9
a plan view of one possible fitment utilized by the post processing fitment applicator of the present invention.
There is illustrated in
FIG. 10
a modified view of the fitment of FIG.
9
.
DETAILED DESCRIPTION OF THE INVENTION
As shown in
FIGS. 1 and 2
, the post processing fitment applicator of the present invention is generally designated
20
. The post processing fitment applicator
20
may be directly downline from a linear form, fill and seal packaging machine, not shown, such as a TETRA REX® packaging machine available from Tetra Pak, Incorporated of Chicago, Ill. In such an arrangement, as soon as the finished cartons exit the packaging machine, the cartons are conveyed to the post processing fitment applicator
20
. Alternatively, the post processing fitment applicator
20
may be placed in a different section of a dairy or like facility in order to isolate the packaging machine or the post processing fitment applicator
20
. Yet, it is not inconceivable to locate the post processing fitment applicator
20
at a completely different site from the packaging machine, such as the final distribution site of the finished product.
The post processing fitment applicator
20
generally includes a housing
21
, a conveyor system
22
, a continuous track
24
, a supply of fitments
26
, a hot melt dispenser
28
and a plurality of fitment carriers
30
. The housing
21
encompasses the components of the post processing fitment applicator
20
that are involved in the fitment application operation in order to provide an enclosed controlled environment for the application of fitments
40
to cartons
50
conveyed along the conveyor system
22
. The housing
21
not only provides for climate control, it also lessens the amount of contaminants that could interfere with the application operation on the post processing fitment applicator
20
. The housing
21
also creates a safer operating environment for an user of the post processing fitment applicator
20
. On the housing
21
may be a control panel
23
for allowing an user of the post processing fitment applicator
20
to input the necessary parameters such as the conveyance speed, the hot melt temperature, the orientation of the fitment
40
, and the like. The operation of the post processing fitment applicator
20
may be controlled by a programmable logic circuit (“PLC”) that generates the necessary commands and provides safety warnings in order for the post processing fitment applicator
20
to operate in an efficient and safe manner.
The supply of fitments
26
is generally composed of a hopper for the fitments
42
, a delivery chute
44
which transports the fitments
40
from the hopper
42
to a receiving point
46
, and an elevator
48
connected a holding bin
49
and positioned to transport fitments
40
from the bin
49
to the hopper
42
. In operation, the fitments
40
are loaded into the bin
49
for transport to the hopper
42
. The hopper
42
places one fitment
40
at a time onto the chute
44
where upon the fitments
40
are transported to the receiving point for placement on a fitment carrier
30
. The chute
44
may have various orienting components to properly orient each fitment
40
before placement on a fitment carrier
30
.
The plurality of fitment carriers
30
are connected to the continuous track
24
for movement thereabout in predetermined intervals. The continuous track
24
with the plurality of carriers
30
thereon, is disposed to have a portion above part of the conveyor system
22
for application of fitments
40
to moving cartons
50
that are conveyed along the conveyor system
22
. Each of the fitment carriers
30
retrieves a fitment
40
from the receiving point
46
where upon the fitment carrier
30
with the fitment
40
thereon is transported on the continuous track
24
to the hot melt dispenser
28
. The hot melt dispenser
28
applies on predetermined quantity of hot melt to the back of each of the fitments
40
. Preferably, the hot melt may be applied to only a flange portion of the fitment
40
. The hot melt provides the adhesive necessary for the fitment
40
to be attached to the carton
50
. The hot melt may include a tank, a hose and a dispenser gun (all of which are not shown). The operating temperature may vary from 180 degrees Celsius to 200 degrees Celsius. Alternatively, the hot melt dispenser
28
may be replaced with another means for adhesion of a fitment
40
to a carton
50
. One possibility would be to substitute a fitment heater for the hot melt dispenser
28
. Such an alternative would heat the back of the fitment
40
through forced hot air or current induced heating in order to impart sufficient heat to the fitment
40
to commence melting of the thermoplastic fitment
40
.
From the hot melt dispenser
28
, each of the fitment carriers
30
is maneuvered for temporary engagement with a carton
50
in order to apply the fitment
40
to the carton
50
as the carton
50
is conveyed along the conveyor system
22
.
A fitment carrier
30
is illustrated in FIG.
3
. Each of the fitment carriers
30
are generally composed of a body
31
, a fitment holder
32
, a fitment displacement mechanism
34
, a pair of arms
36
a
and
36
b
, and projections
38
a-d
, not shown in FIG.
3
. The fitment holder
32
accepts a fitment
40
at the receiving point
46
through aperture
35
. The fitment holder
32
also holds the fitment on the carton
50
during the initial contact. The fitment displacement mechanism
34
pushes the fitment
40
from the fitment holder
32
onto the carton
50
. The fitment displacement mechanism
34
may be a U-shaped frame
37
with a prong
39
thereon. The projections
38
a-d
act to center the carton
50
for proper positioning of the fitment
40
thereon.
As shown in
FIGS. 4 and 5
, each of the plurality of fitment carriers
30
performs a seven step application operation for application of a fitment
40
to a carton
50
. The term seven step may be a misnomer since the application operation is continuous while each of the cartons
50
is conveyed along the conveyor system
22
at a predetermined rate to match the movement of the fitment carriers
30
. Using the seven cartons
50
a-g
and the seven fitment carriers
30
a-g
shown in
FIGS. 3 and 4
to demonstrate the seven step application operation, the operation begins with a fitment carrier
30
a
aligning itself with a carton
50
a
. The proper alignment is very important to ensure that the fitment is placed over the pre-scored area of the carton
50
. The pre-scored area is a partially incised area which defines the aperture for access to the product contained within the carton
50
. This weakened area allows for a fitment with a plunger, cutting edge or some other means for rupturing the pre-scored area to create the aperture in the carton
50
upon the initial access by the consumer. The area of the carton
50
may also be an aperture with a membrane.
The fitment carrier
30
b
and carton
50
b
demonstrate the next step where the fitment carrier
30
b
begins its descent toward to gable top of the carton
50
b
. The fitment
40
on the carrier
30
b
has yet to contact the carton
50
b
. At the next step illustrated by the fitment carrier
30
c
and the carton
50
c
, the fitment carrier
30
c
centers the carton
50
c
for placement of the fitment
40
thereon. During this step, the fitment displacement mechanism
34
contacts the fitment
40
being held in the fitment holder
32
for displacement thereof.
At the next step, illustrated by the fitment carrier
30
d
and the carton
50
d
, the fitment
40
contacts the carton
50
d
. As the fitment
40
contacts the carton
50
d
, the hot melt begins to adhere to the carton
50
d
in order to create a tight bond between the fitment
40
and the carton
50
d
. The fitment displacement mechanism
34
applies a force on the fitment
40
to ensure a tight bond between the fitment
40
and the carton
50
d
. The fitment
40
is still within the fitment holder
32
during this step.
At the next step, illustrated by the fitment carrier
30
e
and the carton
50
e
, the fitment holder
32
retracts while the fitment displacement mechanism
34
holds the fitment
40
on the carton
50
e
. The fitment
40
should be held for a set amount of time to allow for adhesion to occur between the fitment
40
and the carton
50
e
. At the next step, illustrated by the fitment carrier
30
f
and the carton
50
f
, the fitment displacement mechanism
34
retracts allowing the fitment
40
to adhere to the carton
50
f
. The final step, illustrated by the fitment carrier
30
g
and the carton
50
g
, has the fitment carrier
30
g
returning to its commencement state.
The movement of the fitment carriers
30
in relation to the cartons
50
may be actuated by a camming mechanism or servomotors. The movement of the continuous track
24
with the plurality of carriers
30
thereon may be accomplished by rotating drums driven by a servomotor or central shaft.
As shown in
FIGS. 6-8
, a carton has a gable top
52
with a top fin
54
and a fitment
40
thereon. The fitment
40
should be applied a certain distance from the side panel
56
in order to ensure good pourability. The carton
50
may a pre-scored area, not shown, or have a pre-punched aperture covered with a membrane. The membrane should be composed of a material that may be easily ruptured by the fitment
40
. As shown in
FIGS. 9 and 10
, the fitments
40
may have a tamper evidence means.
From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims.
Claims
- 1. A post processing fitment applicator for applying fitments to each of a series of formed, filled and sealed cartons, the applicator comprising:a conveyor for transporting the series of formed, filled and sealed cartons, the conveyor having a straight-line portion extending along at least a portion thereof; a continuous track partially positioned in proximity to the conveyor, the continuous track having a straight-line portion extending along at least a portion thereof, the continuous track straight-line portion and the conveyor straight-line portion having portions that are coextensive with one another; a plurality of fitment carriers moveable about the continuous track for placing a fitment to a formed, filled and sealed carton, each fitment carrier including a fitment holder for receiving a fitment and holding the fitment on the formed, filled and sealed carton upon initial engagement, a plurality of projections extending therefrom for positioning the carton relative to the fitment to properly position the fitment on the carton, and a fitment displacement element for applying a force on the fitment to secure the fitment on the formed, filled and sealed carton; a chute for delivering fitments from a supply of fitments to each of the plurality of fitment carriers at a receiving point along the continuous track; and a hot melt dispenser disposed subsequent to the receiving point along the continuous track, the hot melt dispenser disposed to coat each of the fitments on each of the plurality of carriers with hot melt, wherein the coextensive portions of the conveyor straight-line portion and the continuous track straight-line portion move with one another so as to apply and secure the fitment to the formed, filled and sealed carton as it moves along the conveyor.
- 2. The post processing fitment applicator according to claim 1 wherein the supply of fitments comprises a hopper connected to the chute, a holding bin, and an elevator disposed to transport fitments from the bin to the hopper.
- 3. The post processing fitment applicator according to claim 1 wherein the conveyor system transports a set number of cartons at predetermined intervals for application of fitments to the cartons.
- 4. The post processing fitment applicator according to claim 1 further comprising an housing encompassing at least the continuous track and the hot melt dispenser.
- 5. The post processing fitment applicator according to claim 1 wherein each of the plurality of fitment carriers are moveable toward and away from the cartons being conveyed on the conveyor system.
- 6. The post processing fitment applicator according to claim 1 wherein each of the fitment displacement elements comprises a U-shaped frame with a projection thereon for engagement with a fitment.
- 7. A method for applying a fitment to a formed, filled and sealed carton, the method comprising:placing a fitment in a fitment carrier being moved along a continuous track, the fitment carrier continuous track moving at least in part in a first straight-line path, the fitment carrier configured to carry the fitment and to convey the fitment in the first straight line path parallel to the continuous track and to move the fitment in a second direction generally transverse to the first straight line path to engage the fitment with the formed, filled and sealed carton; rendering the fitment in an adhesive state; conveying the formed, filled and sealed carton along a conveyor system having at least a portion thereof moving in a straight-line track, the straight-line portion being disposed generally parallel to and in spaced relation to the straight-line portion of the continuous track; conveying the fitment in the first straight line path and moving the fitment in the second direction generally parallel to the first straight line path; centering the fitment on the formed, filled and sealed carton by a plurality of projections on the fitment carrier before applying the fitment; and applying the fitment, by movement in the second direction, in the adhesive state to the carton as the carton is conveyed along the conveyor system, in the first straight line path.
- 8. The method according to claim 7 wherein rendering the fitment in an adhesive state comprises dispensing hot melt to the back of the fitment.
- 9. The method according to claim 7 wherein rendering the fitment in an adhesive state comprises heating the back of the fitment to a temperature greater than the melting temperature of the fitment.
- 10. The method according to claim 7 wherein applying the fitment to a carton comprises engaging the back of the fitment to a pre-scored area of the formed, filled and sealed carton while the fitment is within the fitment holder, and displacing the fitment from the fitment holder by actuation of a fitment displacement mechanism.
- 11. The method according to claim 7 further comprising orienting the fitment prior to placement on the fitment carrier.
- 12. A post processing fitment applicator for applying fitments to each of a series of formed, filled and sealed cartons, the applicator comprising:means for transporting the series of formed, filled and sealed cartons; a plurality of fitment carriers for placing a fitment on a formed, filled and sealed carton, each fitment carrier including a fitment holder for receiving a fitment and holding the fitment on the formed, filled and sealed carton upon initial engagement, a plurality of projections extending from each fitment holder for positioning the carton relative to the fitment to properly position the fitment on the carton, and a fitment displacement element for applying a force on the fitment to secure the fitment on the formed, filled and sealed carton; means for moving each of the plurality of fitment carriers at a movement equal and parallel to that of the transporting means for the series of formed, filled and sealed cartons; a chute for delivering fitments from a supply of fitments to each of the plurality of fitment carriers at a receiving location extending along a generally straight-line path; means for rendering the back of the fitment in an adhesive state; and means for moving the fitment in a direction generally transverse to the movement of each of the plurality of fitment carriers.
- 13. The post processing fitment applicator according to claim 12 wherein the supply of fitments comprises a hopper connected to the chute, a holding bin, and an elevator disposed to transport fitments from the bin to the hopper.
- 14. The post processing fitment applicator according to claim 12 further comprising a housing.
- 15. The post processing fitment applicator according to claim 12 further comprising means for moving each of the cartons toward and away from the cartons being transported by the transport means.
- 16. The post processing fitment applicator according to claim 12 wherein the rendering means comprises means for inducing a current in the back of the fitment to heat the back of the fitment to a melting temperature of the fitment.
US Referenced Citations (13)
Foreign Referenced Citations (2)
Number |
Date |
Country |
WO 9704953 |
Feb 1997 |
WO |
WO9704953 |
Feb 1997 |
WO |