Note: Descriptions are shown in the official language in which they were submitted.
llSS04S
BACKGROUND OF THE I~VENTION
This invention relates to a method and apparatus
for making sealed packages such as are used for storing,
shipping, handling and for supporting for use, after a
three-dimension shaped cover is peeled and removed from
such package, a spreadable product adhering to a
substantially flat base member of such package.
This application, which relates to a method and
apparatus for making sealed packages, is a division of
10application Serial No. 361,060, filed September 25, 1980,
which relates to the sealed packages.
-The packages produced by the method and apparatus
of this invention are particularly suited for storing,
shipping, handling and supporting for use a food product
such as butter, margarine, peanut butter, jelly or other
spreadable products desired to be packaged in measured
predetermined quantities, such as a pat.
At present, spreadable materials, such as butter
and margarine, are packaged and are commercially available
in a variety of individual service portions. In one
package a preformed rectangular shape or pat of butter or
margarine is placed on a base card and a flat piece of
paper is placed over and stuck to the p~t. The pat is
covered on the top and bottom but not on the sides. The
spreadable product is readily removed from the base card
by the user in amounts to suit the userls requirèments
with a knife or spatula after the cover has been peeled
off. Such package is extensively used commercially.
However, the spreadable material is not fully enclosed
in the package nor is the package sealed.
In another commercial package, the pat is
completely wrapped in foil. This package requires the
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user to unwrap the foil which invariably results in the
user getting some of the spreadable material on his fingers.
This is messy and an annoyance. Furthermore, because the
wrapping material is quite flexible, it is usually necessary
to place the opened package on a flat surface such as a
table and to scrape the spreadable material from the paper.
The flexible wrapper does not provide a convenient base
from which suitable amounts of the material can be removed
for use. Moreover, such package requires about ten and
one-half square inches of foil. This amount of foil is not
only expensive but creates a problem of disposing of the
wrap after the pat has been unwrapped. This is awkward,
unsightly, and a further annoyance while dining. Further-
more, should the product such as butter or margarine become
soft, as often happens, the package becomes unusable.
If unopened the soft package ¢an be misshaped and cannot
be re-refrigerated for re-use.
~ Another commercial package used for individual
service portions or pats of butter or margarine includes
a tu~ or cuplike member of vacuum formed plastic covered
with a flat cover of foil, plastic or other material. The
butter or margarine is sealed in the tub. To use the
butter or margarine the user must first strip the cover
off of the plastic tub. Once the tub or cup has been
uncovered, the butter or margarine must be scooped or
scraped out of the tub with a knife or the like. This is
awkward. The product in the corners of the tub cannot be
readily removed and is usually wasted. In addition, the
package is expensive.
In addition to the foregoing individual service
portion butter and margarine packages and the apparatus
for the manufacture thereof, there are in the prior art
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many different types of packaging machines for packing
items between one or more sheets of material such as
paperboard, corrugated paperboard, plastic laminates or
the like. These materials are formable by vacuum, air
pressure, punch pressure, compression and other known
forming means.
In certain prior art devïces for packaging rigid
or non-compressible products, the packages are made from
-two members of roll stock, corrugated card~oard or the
like. The roll stock members are passed through the
machine by a variety of means such as conveyors, clamps,
rollers, etc. The product to be packaged is positioned
between the members of roll stock. The members of roll
stock are bent and formed about the product. The product
acts as a mandrel. The formed roll stock members are
attached to each other either by various types of adhesives
or by mechanical means such as rivets or staples. In
general, the product ~eing packaged is not only rigid, i.e.,
non-compressible, but is relatively large in size.
Furthermore, the package is not used as a support ~or use
of the packaged product nor can such a package~be formed
about a non-rigid spreadable-product such as butter or
margarine.
There is a need for a package for a spreadable
product, such as butter, margarine, peanut butter, jelly
and the like, in which the spreadable product is fully
enclosed within the package but from which the product can
be readily removed and spread. Such package must be
produced from inexpensive materials and must be capable of
being produced at high speed and low cost with the product
packaged therein. Such package, when opened, should
provide a support for the product from which amount of
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the product might be removed as such amounts are required,
such as for spreading on bread, rolls, toast, biscuits, etc.
The instant invention provides an apparatus and method for
the production of such a package.
This invention provides an apparatus for making
sealed packages having means for cutting a relatively thin,
flexible but not necessarily stretchable top sheet to a
predetermined length, means including vacuum means for
transporting and securing the cut flexible top sheet while
such sheet is shaped into a three-dimensional shape, means
for shaping the secured cut sheet into a three-dimensional
shape having flange portions and pleats, the vacuum
transporting means including means for transferring the
formed flexible top sheet to a relatively stiff base member
and means for cohering the transferred formed top sheet to
the base member.
The invention relates to an apparatus for the high.
speed production of sealed packages for the storing, shipping
and handling of individual service portions of a spreadable
product which supports the spreadable product for use after
opening the package. The apparatus is adapted to operate
in continuous uninterrupted synchronized movement with
means for positioning the individual service portions of
spreadable product on the approximate center of a substantially
flat, relatively stiff ~ase member having margins surrounding
the spreadable product. The apparatus comprises: (a2 a
continuous supply of relatively thin, flexible sheet material;
(b) a continuously driven rotatably mounted drum having a
plurality of shaping stations on the periphery thereof;
~c) means for continuously feeding and consecutively cutting
individual predetermined lengths of the sheet material in
synchronization with the rotary movement of the drum;
.
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: . ,
llS~Q4S
~d) guide means for directing each individual predetermined
cut length of the sheet material to the peripheral surface
of the drum in centered register with each of the shaping
stations; (e) each of the shaping stations including a
shaping cavity, and means for creating a vacuum substantially
completely about the peripher~ of the shaping cavity, the
vacuum means adapted to engage the margin portions of the
individual predetermined cut length of said sheet material
at the shaping station and slidably retain the cut length
of material substantially completely about the periphery
of the shaping cavity in a substantially flat configuration
in centered register over the shaping cavity; (f) first
tamper means including a tamper head adapted to consecutively
press each of the slidably retained individual cut lengths
of the sheet material into the shaping cavity at each of
the shaping stations to press the sheet material into a
three-dimensional cover member and to thereafter withdraw
from the formed three-dimensional cover member, the
vacuum means retaining the formed cover member in the
three-dimensional shape within the shaping cavity upon
: withdrawal of the tamper head from the shaping cavity;
- (g~ the three-dimensional cover member having a substantially
flat center portion, a substantially flat margin portion
extending laterally outwardly from the center portion in a
separate plane generally parallel thereto, and side walls
connecting the center portion to the margin portion;
(h) means continuously driving the first tamper means in
synchronization with the rotary movement of the drum so
that the path followed by the tamper head as it travels
into and out of the shaping cavity is always ma;ntained
along a radial line extending through the axis of rotation
of the drum and the center of the shaping cavity and the
,
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115S045
tamper head is maintained substantially perpendicular to
the radial line while forming the sheet material into the
three-dimensional cover member, the tamper head consecutively
traveling into and out of each of the shaping cavities
during continuous rotation of the drum; (i) the vacuum
means slidably retains the margin portions of the sheet
material on the peripheral surface of the drum while the
tamper head presses the remaining portions thereof into.
the shaping cavity and thereafter holds the margin portions
la of the formed cover member in a fixed position thereby
maintaining the.thrèe-dimensional shape of the cover member
upon withdrawal of the tamper head from the shaping cavity;
(j) means continuously transporting the base members at
uniformly spaced intervals to a position tangentially
adjacent the peripheral surface of the drum in synchroniza-
tion with the rotation of the drum so that each of the
three-dimensional cover members is transported by the drum
into moving register with one of the moving base members,
the moving register between the cover member and the base
member locating the center portion of the cover member
: over.the spreadable product carried by the base member
: without deforming the spreadable product; (k) means for
releasing the cover member from the drum upon being
rotated into moving register with.the moving base mem~er,
the release means comprising means for breaking the vacuum
while substantially simultaneously compressing the margin
portions of the cover member onto the margins on the base
member; and (.1) means for removably sealably adhering the
margin portions of the released cover member to the margins
on the base member upon compression thereof to sealingly
enclose the spreadable product therebetween.
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In its method aspect the invention relates to a
method for high speed production of a sealed package for
storing, shipping and handling an individual service
portion of a spreadable product and for supporting the
spreadable product for use aftèr opening the package,
comprising the steps of: (a) continuously transporting
a plurality of shaping cavities to a shaping station at
uniformly spaced intervals; (b) continuousl~ feeding a
supply of relatively thin, flexible sheet material;
~c) consecutively cutting individual predetermined lengths
of the sheet material from said supply thereof; (d) directing
individual predetermined cut lengths of the sheet material
to the shaping station at uniformly spaced intervals of
time; (e) synchronizing the movement of the shaping cavities
with the speed of the feeding and cutting of the sheet
material so that each of the individual cut lengths thereof
is deposited in center register over one of the shaping
cavities; (f) applying a suction substantially completely
about the periphery of each of the shaping cavities so as
to pick up and slidably hold the margin portions of the
individual cut length of sheet material and cause the.
material to lie in a substantially flat configuration in
centered register across the shaping cavity; (g~ forcing
the sheet material into the shaping cavity while the
cavity continuously moves through the shaping station and
while simultaneously continuing to apply the suction to
the periphery of the shaping cavity, thereby causing the
margin portion of the sheet material to slide longitudinally
and transversely inwardly along the plane of the periphery
of the shaping cavity while the center portion thereof is
pressed into the shaping cavity to form the sheet material
into a three-dimensional cover member having a substantially
~55~4~;
flat margin portion extending laterally outwardly from
the center portion in a separate plane generally parallel
thereto, and side walls connecting the center portion to
the margin portion; (h~ removing the force from the formed
three-dimensional cover member while continuing to apply
the suction to the margin portion of the cover member,
the suction fixedly retalning the cover member in the
shaping cavity in the three-dimensional shape; (i) inverting
the shaping cavity while the cover member is fixedly
- retained therein so that the center portion of the cover
member is positioned above the margin portion thereof;
(j) at a station remote from the shaping station, placing
an individual service portion of a spreadable product on
the approximate center of a substantially flat, relatively
stiff base member having margins surrounding the spreadable
product; (k) continuously transporting the base members at
uniformly spaced intervals into moving register with the
inverted cover member fixedly retained in the shaping
cavity; ~1~ releasing the inverted cover member from the
shaping cavity; (m) compressing the released cover member
on to the base member so that the center portion thereof
: ~ covers the spreadable product carried on the base member;
and (n) removably sealably adhering the margin portion of
the cover member to the margins on the base member to
sealingly enclose the spreadable product therebetween.
BRIEF DESCRIPTION OF THE INVENTION
Thus, the invention relates to a method and
apparatus for making sealed packages for storing, shipping,
handling and supporting for use, when peeled open, for an
individual portion of a spreadable product. The invention
is particularly suited for use with a mechanism where a
serving portion of a spreadable product such as a butter
or margarine pat has been placed on a relatively stiff
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base member, such as coated paperboard, so that there are
flanges or margin portions on the stiff base surrounding
the spreadable product. There is a supply, such as a
roll, of relatively thin flexible material, such as paper,
which will form the top sheet of the package and means
for feeding the top sheet material. The top sheet material
is cut into predetermined lengths and transported and
shaped into caps. The transporting and shaping means,
in the preferred embodiment, includes a rotatable vacuum
drum member having a plurality of spaced die stations on
its periphery. The cut top sheet is directed to the
rotatable vacuum drum and is picked up and held thereon
by vacuum in register with a die station. The cut top
sheet is rotated to a shaping position where a first tamper
contacts the center area of the cut sheet length, pressing
the center area of the sheet into the recess in the shaping
station and shapes the cut sheet length into a three-
dimensional shape, substantially the same shape as the
final shape of the cover. The marginal portions of the
sheet surrounding the center area forced into the shaping
stations recess are held by the vacuum. The shaped top
member is transported into register ~ith the stiff base
member carrying the spreadable product so that the cohesive
coated marginal portions of the shaped cover match the
cohesive coated marginal portions of the ~ase member around
the product. The leading and trailing marginal portions
of the top sheet and base member are pressed together and
cohere. At various points the marginal portions of the
top sheet are folded into pleats away from the base member.
Subsequently an ironing roller presses the side margins
together and resiliently mounted blades thereon further
press the leading and trailing margins. There is a second
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tamper which tamps the pleats toward the base member and
closes the terminal ends of the pleats and sizes the height
of the package. With some packages, the second tamper
may also shape as well as size the package.
The instant invention will be better understood
from the following description, taken with the appended
drawings, of a preferred embodiment of the invention in
which:
Figures 1 to 6 describe the package and parts
thereof claimed in the parent application wherein;
-Figure 1 is a perspective view of the top or
cover sheet of the package;
Figure 2 is an exploded perspective view of
elements of the sealed package before assembly showing the
top or cover sheet formed and the product to be packaged
on the relatively stiff base;
Figure 3 is a perspective view of the package in
sealed condition;
Figure 4 is a perspective view of the package
20 showing the top sheet being peeled from the base and
: product;
Figure 4A, located on the third sheet of drawings, .
is a perspective view similar to Figure 4 but showing a
modified form of the package;
Figure 5 is a top view of the package of Figure 3;
Figure 6 is a botto~ view of the package of
Figures 3 and 5;
Figure 7 is a perspective view. of the feeding
and shaping apparatus Oc the invention;
Figure 8 is a side elevation of the apparatus of
Figure 7.
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Fi~ure 8A, located on the third sheet of drawings,
is a side elevation view of a modified ~orm of the apparatus
of Figures 7 and 8;
Figure 8B, located on the third sheet of drawings,
is a side elevation view of a portion of the apparatus of
Figure 8A but in a different position;
Figure 8C is an end view of the apparatus of
Figure 8A;
Figure 9 is an exploded perspective view of the
shaping drum of Figures 7 and 8;
Figure 10 is a sectional view taken along lines
10-10, Figure 8;
Figure 11 is a sectional view taken along lines
11-11, Figure 10;
Figure llA, located on the sixth sheet of drawings,
is a sectional view of a modified portion of the apparatus
of Figure ll;
Figure llB, located on the sixth sheet of drawings,
is a sectional view of the modification of Figure llA but
taken at a different position;
- Figure 12 is an exploded view of a portion of
the pat conveyor;
Figure 13 is an elevation view showing the tamping
apparatus;
: Figure 14 is a side elevation view of the apparatus
of Figure 13 taken from the left as viewed in Figure 13;
Figure 15 is a modified form of the apparatus of
Figure 13; and
Figure 16 is a sectional view taken on 16-16,
Figure 15.
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1155~45
DETAILED DESCRIPTION OF THE INVENTION
_
Referring to the drawings, particularly Figures 1-6,
the package and parts thereof claimed in the parent
application are described to facilitate understanding of
the present invention. There is shown a relatively flat,
relatively stiff base member, generally designated 2,
which, as shown, is rectangular in shape although the
parent invention is not limited to a rectangular shape.
Preferably, the base is made of paperboard, or the like,
coated with a grease resistant coating and, in one preferred
embodiment has a thickness of about ten and one-half (10.5)
mils.` The base member 2 on its upper surface has a coating
of a cohesive material which is cohesive to itself and
adhesive to the base at the time of coating but otherwise
non-adhesive. The use of a cohesive coating has the
advantage that two members so coated can be cohered to
each other at extremely high speeds by applying a small
amount of pressure and without the necessity of heat. The
importance of eliminating heat and heat activated adhesives is
that not only must the heat pass through the material on
which the adhesive is coated but must then be cooled.
Because the rates of speed at which the packages of the
parent invention are produced are in the neighborhood of
1500 units per minute in a single line, heat sealing becomes
a practical impossibility for the equipment used to
manufacture the packages.
As shown, there is positioned in the approximate
center of base 2, product 6, such as a pat of spreadable
material, e.g., margarine, butter, peanut butter, jelly,
or the like. The parent invention, however, is not limited
to spreadable food products and could be used to package
artists' paints, salves, ointments, creams, putty ar other
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~SS~45
products which are customarily applied with a knife,
spatula or other similar type instrument.
The spreadable product, at normal use temperature,
adheres to the base member and will remain adhered to the
base member regardless of the orientation of the base
member until removed by a knife or spatula.
The product is positioned on the base so as to
form margin portions 8 around the product extending to the
periphery 10 of the base. The parent invention further
includes a top sheet 12 which is relatively thin, relatively
flexible and non-stretchable. The top sheet, in one
preferred embodiment, is made of glassine paper having a
thickness of about two (2) mils. The top sheet must be
flexible and capable of being shaped, as shown in Figure 2.
The top sheet 12 is substantially rectangular and of such
dimensions so that peeling tabs, subsequently described,
can be formed. The top sheet is also coated, on its under
surface facing base 2, with a cohesive 4 such as used on
the base. The cohesive 4 must be adhesive to the top
sheet at the time of coating and cohesive to cohesive 4
on base 2 but otherwise non-adhesive. When the cover
mem~er is peeled from the base and the package product,
the cohesive on base and top sheet 12 should part without
delamination or peeling of base 2 or top sheet 12.
Preferably as best shown in Figure 4A, cohesive 4 on top
sheet 12 is applied in dots 4a substantially e~ual in size
~and substantially evenly distributed. Cohesive dots of
about .020 in. diameter, spaced 1/32 in. on centers have
been found acceptable. Rather than applying the cohesive
in dots to cover 12, the cohesive might be so applied to
base 2.
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~lSS~4S
The top member is shaped in some measure in the
form of the product being contained, shipped, stored and
handled, resulting in a compact, attractive package. This
might be accomplished, as later explained, before the
top member is applied or might be partially accomplished
before the cover is applied with final shaping as the
package is completed.
As embodied and shown in Figure 3, the top member 12
is so shaped as to include a center portion 14 which is
relatively flat, rectangular in shape and substantially
coextensive with the pat 6 of spreadable material. Extending
downwardly from the peripheral edges 16 of the center
portion 14 are sides 18. The angle of the sides is not
critical and could be at right angles to the center portion
14. The downwardly extending sides 18 terminate in flange
or margin portions 20 which extend substantially parallel
to center portion 14 and to the peripheral edges 22 of base
member 2. It is within the scope of the parent invention
for the flange or margin portion 20 to extend slightly
short of, to, or slightly beyond the peripheral edges 22
o~ base member 2. The flange or marginal portions of the
top sheet are in face-in-face contact with the marginal
portions of the base, Figures 3 and 4. Because these
surfaces are cohesive coated, top member 12 and base 2
are cohesively joined around pat 6.
In accordance with the parent invention means are
provided for forming flaps or tabs on the top member which
flaps or tabs are used to separate the top sheet from the
base and product by grasping any one of the flaps or tabs
and peeling the top member from the base member and product
thereon. As embodied and best sho~n in Figures 5 and 6,
such means comprises a plurality of pleats or folds 24
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having end portions 26, at least one of which ends extends
beyond the edge of the base forming readily accessible
means for peeling and removing top cover member 12 from
base 2 and pat 6.
As shown in the drawing, there are four pleats
or folds 24 each of which begin at a corner of the center
portion 14 and terminate a relatively short distance from
the adjacent corner of base member 2. One side 28 of
each pleat 24 is substantially parallel to the adjacent
edges of top sheet 12 and base member 2 and is, in effect,
an extension of its connecting side wall 28. Such side 28
extends a short distance beyond the edge of base member 2
forming the accessible peel tab 26.
It is not necessary that pleats or folds 24 be
formed adjacent the corners. It is contemplated that such
pleats could be formed, along the sides intermediate the
corners. However, forming the pleats adjacent the corners
as shown in the drawings constitutes the preferred
embodiment of the parent application. The pleats or
folds 24 are flattened at their terminal ends 30, Figure 3,
so as to complete the sealing of the package.
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~L~55045
Certain advantages flow from the peeling tabs being located
adjacent the corners of the base member.
When peeling top member 12 from base member 2, Figure 4,
it is necessary that top member 2 be removed in such a manner that
product 6 remains on base member 2. With a spreadable product, such
as, margarine, butter, peanut butter and the like, it is obvious
that when product 6 remains on relatively stiff flat base member 2
the product can be removed therefrom much more readily, easily and
completely than from any cup-shaped member as in previously mentioned
types of single portion packages, such as tubs or foil wraps.
Product 6 when in the form of a parallel sides pat, has a
relatively large substantially flat surface in engagement and adhering
to base member 2. In addition, the peel tabs are positioned and
arranged so that cover member 12 when peeled from base member 2 will
peel from one corner to the diagonal opposite corner. In this manner,
the flexible thin cover peels from pat 6 without peeling far thicker
pat 6 from base member 2. Because the surfaces holding the product
on the base are larger than the line along which cover member 12
is peeling from base 2 and pat 6, the result is that pat 6 stays in
place on base regardless of orientation of the base until pat 6 is
wholly or partly removed by a knife, spatula or similar instrument.
~ he method and apparatus for producing the sealed packages
of the patent invention will now be described. Referring to the
drawings, particularly Figures 7-14, there is shown a stationary
frame 32 on which is mounted rotatable roll stock supply member
34 containing a supply of relatively thin flexible
.
- mg/~ - 16 -
~L5S~45
,, top sheet material 36, such as paper, which will be shaped into
the top sheet member 12. Conventional brake means 38 engages
! fle~ible ma~erial 36 to prevent unwanted unwinding of material ~6
~! from roll stock 34
Ij -
Top sheet material 36 is fed by a pair of feed rollers
' 40, Figure 11, driven by gear train 42 and main gear 43, Fi~ure 7.
Gear train 42 also drives roller 44, Figures 7 and 11, having
i! ~nife 46 attached thereto, Figure 11. Knife 46 cuts top sheet
I¦ material 36 into pxedetermined leng~hs after material 36 passes
¦j through feed rollers 40. The cut top sheet 36 is then guided by
~ guides 48, Figure 7, to vacuum drum means generally designated S0.
ii Vacuum drum means 50, Figures 9-11, includes a circular
;~ manifold 52 fixedly attached t'o frame 32 in any convenient manner.
Through aperture 54 and cir'cular chamber 53 circulzr ~.anifold 52
'. communic'ates with a vacuum source, not shown, for purposes
explained subsequently. Through vents 55 and 57, Figures 9 and
11, vacuum chamber 53 is vented to the surface or manifold 52
around the periphery of shaping stations 58 for purposes later
' described. Vents 55, Figure 11, may be to flats at the leading
and trziling ends of s~aping staLion 58 in dru~ 56 or may be to
: the arcuate surface of drum adjacent the ends o~ shaping station
58 as best'shown at 55', Figure llA.
!i : Mounted in'telescoping relationship over manifold 52
~¦ and mounted for rotation thereon, is drum 56 having a plurality
,~ of die or shaping stations 58 spaced equally about lts periphery.
'~ While, as shown, there are six such stations there could be a
'', greater or lesser number of such stations depending on the drum
:
~1~55~45
si~e and the drum speed. Connected to the inner surface of the
vacuum drum 56 is a sealing ring or gasket 60 attached to drum 56
for rotation therewith by screws 64 or the like. Sealing ring or
gasket 63 is mounted in fixed position on manifold 52. Gaskets
60 and 63 form a vacuum tight seal between stationary manifold 52
and rotating drum 56 for purposes more fully described later herein.
Gear 43 is mounted to the outer surface of drum 56 and attached
to drum 56 and gear 66, Figures 9 and lO, by cap screw 68. Gear 66
is driven by pinion 70 attached to the drive shaft 72. As best
shown in Figures 9 and 11, sealing shoe 73 is urged by leaf spring
75 into engagement with the inner surface of drum 50 to form a
vacuum tight seal therewith for purposes later described.
Tamper 74, Figure 8, is mounted on rod 75 attached by
pivot 80 to drive disc 76 and slidably in guide 82 pivotally
mounted on guide disc 78. Discs 76, 78 are driven by a conventional
gear train, not shown, which in turn is driven from gear 43O The
rotation of the discs 76, 78 causes essentially vertical movement
of the tamper 74. The terminal end 86 of tamper 74, Figure 11,
is attached by screws 88 and biased by spring 90. Terminal end 86
which, preferably is made of a low friction or self-lubricating
material, such as nylon, includes a downwardly extending head
portion 92 and an outwardly extending flange portion 96.
Each of the shaping stations 58 on vacuum drum 56
includes a flat center portion 98, Figure 9, inclined leading and
trailing walls lO0, 102, Figure ll, and inclined side walls 104,
Figure 10. Spaces or gaps 106 are provided in the surface of
,
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55~45
. . .
¦ drum 56 between the ends of inclined side walls 104 and inclined
~¦ leading and trailing walls lO0, 102 as best.seen in Figure 9.
i' Referring to Figures 8A, 8B dr~ms 77,77' are mounted
'¦ for rotation and vertical adjustment on fixed housing 7~ by
~! adjustment thumb screw 81 and lock screws 83. Plates 85, 87, 89,
ii 91 are mounted on drums 77, 77' by pins and plate slots and 2re
' spring urged outwardly of the periphery of drums 77, 77' by pairs
of compression springs mounted in drums 77, 77' at the inner ends
1 of the plates. Drums 77, 77' are dri~en by gear 93 in turn
¦ driven by gear 95 from gear train 42 and in timing therewith.
¦ Back up rolIer lOl, 101' are mounted on shaft 103 of pivoted
,~ arms 105, lOS', pivoted at 107 to the stationary fra~e. Back up
Il rollers 101, 101', with drums 77, 77', as will be later described,
engage the longitudinal edges of base member 2 and cover member
.. j 12. Pivot arms 105, 105' and back up rollers 101, 101' are
adjusted so that rollers 101, 101' engage the longitudinal edges
ii of the base and co~er members with drums 77, 77' by adjustment
scre~s 107, 107'~ Carrier 112 is ca~,ed up to engage the leading
: ` and trailing edges of base member 2 and co~er ~ember 12 with the
ecges of ~lates 85,87, 89, 91 by cam 10~ adjusted by 2djusting
. screw 111.
,'i - The apparatus and sealed packa~e of the instant inven-
i tion is particularly 2dapted for use with the apparatus sho~m and¦~ described in United States patent No. 3,129,546 issued April 21,
1964.~ The apparatus shown and described in that patent plaoe s individual
i~ portions of a spreadable product such as butter or margarine, on
. . .
. .
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. . .
: i
~; ~.155`~145
., .
. a relatively stiff base member which showing and description is
incorporated herein.
As sho~m and described in more detail in patent No. .
. 3,129,546, pat 6 of butter,margarine, or the like, is formed and
deposited on base 2 on conveyor llO having carriers 112 thereon
. for receiving and conveying base 2 Each of the carriers 112
has a clip 114 thereon for engaging the trailing end of base
j member 2 carried thereon and fed by conveyor llO in the direction
¦l of the arrows, Figure 11. ¦
il The pat forming and conveyor 110 dri~ing appaxatus of
~, the '546 patent and the apparatus of the instant application are
driven from a common drive source, such as an electric motor, not
' shown, and are geared together so that ,he carriers 112 and pat 6
therein are each registered~with 2 shaping station 58 on drum 56
as drum 56 rotates in the direction or the arrow, Figure 11, and
conveyor llO advEnces carriers 112 and pa, 6 past drum 56.
With d~um 56 rotat~ng in registry with conveyor 110 and
carrierS 112 thereon, flexible top shee~ material 36 is fed fro~
roll stock 34 through feed rollers 40. The leading end of sheet
~Steri2l 36 is cut by knife 46 into 2 pre-set length w~ich, 2S
wilL now be described, is shaped, transferred and adhered to base
2 ov~r pat 6 on carriers 112 as the shaping station 58 carrying
.~ the cut and shaped length registers with base 2.
,i As the pre-set length is cut rom the leading end of
material 36, the cut sheet is guidPd by guides 48 into engagement .
; with rotating dru~ 56. The rotation of drum 56 and the feeding
and cutting of material 36 are timed so that guides 48 engage
the leading and trailing edges and side edges o~ the cut sheet
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over through vents 55, 57. Thus, the vacuum in chæmber 53,
! through vents 55, 57, holds the cut sheet in registry o~er the
il center portion 98 and inclined walls 100, 102, 104 of the regis- ~,
tered shaping station 58. As each shaping station 58 is rotated
in the direction of the arrow, Figure 11, past guides 48, a pre-
set length of sheet material 36 is fed by rollers 40, cut by
I knie 46 and deposited on rotating drum 56 in registry with a
i registered shaping station 58.
I As best shown in Figure 11, the cut length of sheet
¦ material 36 extends substantially planar across shaping s~ation
58 and is held thereacross by vents 55, 57 and the vacuum therein.
, As each shaping station 58 is rotated in the counter-
, clockwise direction, as sho~m by the arrow, Figure 11, under
tamper 74, drive disc 76 and~ guide disc 78, which are continuously
', driven in synchrony with drum 56, advances terminal end 86 of
tampex 74 into engagement with the sheet material. The dowmwardly
extending rectangular head portion 92 of tamper 74 pushes the
center portion of the sheet into the, shaping station recess toward
.~ ~lat center portion 98. As the center portion of the flat sheet
~s pushed toward the flaL center portion ~8 of t'ne sha~ing station
r,ecess, the leading and trailing edges,and side edges are rorced
downward by outwardly extending flanges 96 against vacuum vents
, 55, 57. Between the leading and trailing edges and side edges,
il the sheet material is folded into pleats or folds which extend
into gaps 106 between the edges. These pleats or folds form
'; the pleats or folds 24 in the sealed package assembly.
i, , Ta~per 74 is driven and synchronized to move inward and
outward as each shaping station 58 is rotated past the tamper.
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Tllus, as drum 56 rotates past the tamper, tamper 74, which is
advancing, forms the sheet material in the die at the shaping
station and is withdrawn. The rotary ~otion of drum 56 and the
in~7ard and outw2rd reciproczting motion of tamper 74 is, of
course, continuous.
The sheet material, shaped into cover member 12 in
shaping station 58 by tamper 74 is rotated downward, in the coun-
terclockwise direction, Figures 8 and 11, and as it approaches
¦¦ the six o'clock position, the leading edge of cover 12 engages
tO ¦I the leading end o base 2 advancing on conveyor 110. As base 2
! is advanced on conveyor 110 to~ard drum 56 and just before the
leading end of base 2 contacts the leading edge of cover 12, the
leading end of base 2 contacts and is raised slightly off o~
carrier 112 by-rollers 91, 91a at the opposite sides of conveyor
; 110 and carrier 112. Rollers 91, 91a, 92 are spaced so as to
clear conveyor 110 and carrier 112 but to contact .he longitudinal
' edge portion of base member 2 and cover member 12 as ~he base
~-.ember and cover Fle~bers are brought together.
,. Rollers 91, 91a, Figure 8, are mounted for rotation,
reicpectively, on arms 94, ~4a pivoted at 9, 99a and spring
urged, respectively, by springs 104, 104a mounted on bases 108,
;' 108a in a counterclock~ise direction toward the base and cover
j, members longitudinal edges 2nd drum 56. Thus, the lontitudinal
" edges of base member 2 and cover member 12, as such edges are
brought together, pass between the surfaces of rollers 91, 91a
2nd drum 56. As drum 56 rotates and longitudinal edges of base
member 2 and cover member 12 pass therebetween, rollers 91, 91a
are urged in a cloc~wise direction, Figure 8, compressing springs
104, 104a.
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.l At about the time the edges of cover 12 are brought
into engagement with the edges of base 2 between rollers 91, 91a
j and drum 56, vacuum vents 55, 57 pass beyond vacuum chamber 53,
', Figure 11, the vacùum is broken and the cover is released. The
;I cohesive coatings on the contacting surfaces of cover 12 and
~i base 2 brought into contact by the registry of shaping station 58
! on rotating drum 56 with base 2 on carrier 112 of conveyor 110
¦ and passing between rollers 91, 91a and drum 56 coheres cover 12
Il to base 2 around product pat 6. From drum 56 and rollers 91, 91a,~
~I base 2 with cover 12 around pat 6 thereon is advanced to drums
! 77~ 77'. Drums 77, 77' are, of course, rotating and are timed
with respect to the advance of conveyor 110, carrier 112 and base
2 so that, as the leading.end of base 2 approaches drums 77, 77',
' the leading end of plate 91 in rotating drums 77, 77' engages the
leading end of cover 12. Plate 91 is pushed into the slot against
the co~ression OL the springs and the leading edge of cover 12
is cohesively af~ixed to the leading edge of base 2. As conveyor
110, carrier 112 and base 2 continue to advance and drums 77, 7i'
' con~inue to rotate, the longitudinal edges of base 2 and cover 12
p2SS between drums 77, 77' and back up rollers 101, 101'. Dr~ms
. 77, 77' and rollers lOl,lOl' cohere the longitudinal edges. The
leading edge o~ plate 89 in rotating drums 77, 77' engages the
trailing end of cover 12 cohesively affixing the trailing end of
i the cover to base 2.
. ' From rotary drums 56, 77, 77' the covered pat is
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ad~anced on carrier 112 by conveyor 110 to a second tamper down-
stream of drums 56, 77, 77' and generally designed 130, Figures 8,
13 and 14. Tamper 130 includes a tamper head 132 of low friction
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1155~45
or self lubricating material, such as nylon, h~ving a raised
. center portion 134 and do~wardly extending side walls 136, 138
!~ extending longitudinally in the direction of travel of conveyor
110 and spaced apart so as to clear pa~ 6 and raised center
portion 14 OL the package assembly but, at the same time, close
enough to contact the longitudinal flanges o the package. Tamper
~i 130 is connec~ed by tamper rod 140 and pivots 142, 144 to
l rotating discs 146, 148. Discs 146, 148 are driven continuously
¦ by gearing, not shown, fro~ the drive of drum 56 and conveyor 110 i
and are synchronized therewith. As a cover package from drums
56, 77 approaches tamper 130, tamper head 132 is advancing
il downwardly. As the covered package moves under an~ passes tamper
130, downwardly moving side walls 136, 138 of tamper 130 engage
the upstanding pleats or folds 24 in cover sheet 12 to collapse
, and seal the folds, sealing cover 12 on base 2 forming a sealed
enclosure about the product pat 6 therein. As conveyor 110
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advances the sea~ed package away from tamper 130, .amper head
132 is elevated by rotating discs 146j 148.
i'In the embodiment of Figures 8, 13 and 14, the edges
~0 and ple2ts or folds 24 in cover sheet 12 are sealed on base 2
, around product pat 6 thereon. Thus, raised center portion 134
. is raised and remains above and spaced from the top of the pat
il when the pat is tampered. In some instances, especially in
larger-pats, for example four ounce pats, shaping and sizing of
the pat during final tampering might be desired. To accomplish
such sizing and shaping tamper head 132', Figures 15, 16 has a
raised c.enter cavity 1-34' surrounded by down~ardly extending side
walls 136', 138' and end walls 139',141. Center cavity 134' and
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walls 136', 138', 139',141 are shaped so that, as the ends of
walls 136', 138', 139', 141 are brought into engagement with the
outwardly extending edges of cover 12 on base 2 around product
pat 6, cover 12 engages the dome of cavity 134' and the walls to
size and shape the pat. In such instances, of course, the
product initîally formed and deposited on base 2 is of a volume
co~mensurate with the size and shape to be eventually formed at
'~ taF.per head 132'.
The sealed packages advanced from tamper 130 may be
0 li carried out by hand or by machine such as the counter, stacker
,~ and packager in U. S. patent No. 3,631,652.
, There are numerous cohesive coatings which might be
1~ employed in the practice of the inst2nt invention to cohere cover
I member 12 to base 2. In se]ecting a cohesi~e material, a material
which is compatible to the materials of the cover and the base,
; will form strong adhesive bonds therewith and is acceptable for
; use with the foo~ being p2ckaged should be selected. Preferably,
.ne cohesive material should be cohesive to itself but not to
~, o,her materials and should be dry to the touch. ~hen cohered to
itself, such as be*ween co~er ~ember 12 znd base 2, the materials
~nould be firm and hold the ~embers together. However, when cover
member 12 is peeled from base 2 and pat product 6 pacXaged therein,
such cohesive coatings should part without tearing of the cover
sheet or delaminating base 2. The cohesive should, of course,
adhere to the sur,ace of the base and cover which ~ay be of a
grease repelling material or coated with such ma,erial. As
already noted, it is preferred to apply the cohesive to either
t:~e base or cover, and preferably to the cover, 2S a series of
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uniform, equally spaced dots. For purposes of storage and
handling before formed into the package, the adhesive might be
coated with a parting agent which, of course, should not interfere
~ with cohesion -~ihen the base and cover are brought together.
: The terms and expressions which have been employed
are used 2S terms of description and not of limitation and there
is no intention, in the use of such terms and expressions, of
,3 excluding any equivalents of the features shown and described or .
¦¦ portio~s thereof, but it is recognized that various modifications ¦
I are possible within the scope of the invention claimed.
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