Note: Descriptions are shown in the official language in which they were submitted.
-
~THOD ~ND APPARAT~S FOP~ FO~NG
A CONTAINER FOR LIQ~IDS
Bac~:ground of the Inventi~n
~.S. Patent N~. 3,~0D,677 granted April 2, 1974 to
Charles t~. Jones and ~ight La Stetler discloses app~ratus
for fo-ring, an~ ~.S. Patent No. 3,775,943 granted
Decerber 4, 1973 to Charles WO Jones discloses apparatus
~or filling and sealing straw-~earing cartons. The
apparatus and m-thod of the pxesent in~ention, to be
described hereinafter, are intended to form, fill, and
~eal si~ilar cartons. T:~e car~on formed by the apparatus
and m,ethod of the present invention i5 the type disclosed
; in U.S. Paten~ ~'o. 3,749,330 qranted July 31, 1973 to
15 Charles t~. Jones as ~:ell as ~he i~?rovements thereon as
shown in U.S. Patent No. 4,011,984 ~ranted to Mato~ich,
Jr. issued ~1a~ch 15, 1977.
This a~plication is related to Canadian a?plication
356,391 and 356,~98 filed July 17, 1980 respectively.
Basically, the car,on disclosed in each of these
patents and a?~lications comprises a rec,an~ular cross~
~ection container ~or~d from a one-piece, su~stantially
T~sh2ped blank of polye'hylene co2ted paperboard. The
25 carton may be provided on ~ne of its sides with an acoess
flap to the inside of which is atta~hed a straw element.
The liquid contents of the carton may be consumed ~y
; lifting the access flap, thereby rotating the etraw to
exp~se ~ne end ~L ~he straw ele;~.ent rom which the
3~ contents of the carton m2} ~e dratm into the ~outh, and
lowering the other end of ~he straw into a corner of the
car on.
In the formation of the carton by the apparatus sh~m
in 1~.5. Patent t~c). 3,800,667, ~Dth ends c~f the carton
blank are sealed prior to ~h~ filling ~peration.. A5
disclosed in U.5. Patent N~. 3,7~5,943, the access flap
is lifted and the carton filled therethrough, after which
, , ;.. . :-
~S~75
the aperture is sealed by the application of a length
of tape. U.S. Patent No. 4,037,370 discloses apparatus
for closing and sealing the carton wherein the carton
5 is filled from the top of the container and subsequently
a cover member is pressed flat down upon the open end o .
the filled carton and sealed there-to by the melting and
cooling of the polyethylene coating on the top of the
open~ended Garton. Although these prior art me-thods and
10 apparatus for forming the carton have proven useful in
- their limited application, they have presented certain
cost, space, and production and reliability problems.
In par-ticular, the prior ar-t apparatus for forming
the carton has required an extremely large and elongated
1~ structure wherein aZn individual carton blank was formed,
filled, and sealed by progression through a series of
work stations oriented in an extended production line
manner. This large and elongated structure re~uired a
Z considerable amount of space within a plant facility to he ~' 20 devoted to the apparatus, which detracted from the
overall efficiency of the device and permitted the
installation of the apparatus in only large production
facilities.
Further, the prior art apparatus typically
25 facilitated the formation, filling, and sealing of the
carton in a serial manner along the production line (i.e~,
one carton being formed at a time) which, due to the time
required for filling and sealing of the carton,
limited production output and necessarily increased
30 production costs.
Additionally, due to the elongate na-tuxe of the
apparatus for forming the carton and the intricate
mechanical mechanisms and extended transport mechanisms
utilized therein r one or more skilled technicians were
35 required to constantly moni-tor and fine tune the apparatus
during operation. Further~ the prior art apparatus was
incapable of providing a simple ana convenient method of
accommodating di-EEering sized containers for different
production runs As such, the versatility of the prior
art apparatus was severely limited.
Summary of the Present Invention
The ~pparatus and method of forming a caxton blank
which is the subject of the present invention is a
significant improvement over the apparatus and methods
disclosed in -the hereinbefore-identified patents and
patent applications and significantly eliminates the
deficiencies associated with the prior art. The present ¦
i.nvention p:rovides a compac-t apparatus for forming a
carton wherein a substantially T-shaped carton blank is
provided with a straw element and tape seal, creased into
a square, tubular configuration about a forming mandrel,
sealed along its side and one end by an ultrasonic welding
-, process r pre-formed along its open end by a sexies of
dies, filled with a desired liquid by a two-stage filling
process, and subsequently sealed along its open end and
automatically ejected from the apparatus.
The significant reduction in spaee and compact nature
of the apparatus of the presen-t invention is made possible
by the -transverse orientation of the mechanism for applying
and sealing the straw element to the carton blank with the
remainder of the appara-tus of the machine~ This transverse
orientation allows the carton blanks to be serially ~one
at a time) provided with the straw element and tape seal
and subsequently travel in a plurality (in the preferred
embodiment four at a -time) through parallel sealing and
filling sta-tions. Since the majority oE the production
time is consumed in the sealing and filling operations,
this plural transport of the cartons through the remainder
of the apparatus significantly increases production
output of the apparatus, without unnecessarily duplicating
the pxeliminary s-ta~es which are capable o-f high speed
operation. As such, the apparatus of the present
invention may be eEfectively utilized in smaller plant
facilities and provide a high production output which
heretoEore could no-t be accomplished by the prior art
apparatus, ~ithout unnecessary cost increases.
Additionally, the present invention, due to its
compact size, significantly reduces the col~plexities of
the transport mechanisms as ~ell as the len~th of
transport of the carton blanks through the apparatus
This reduction of the transport mechanisms substantially
reduces the possibility of misalignment of the carton
blanks traveling through the apparatus ~nd, as such,
provides greater consistency in production output.
Addi-tionally, the present invention, in the preferred
embocliment, is provided ~Jith a central hydraulic drive
system which powers the major transport systems with
the individual work stations along the apparatus being
:r 20 pneumatically operated to yield greater reliability for
-the apparatus.
In the preferred em~odiment~ the apparatus and
method of the present invention proviae a novel tape and
straw seal mechanism which bonds and seals a straw
element and tape length over the aperture for~ed in one
side of the carton blank while the unfolded, T-shaped
carton blank is positioned upon a rotating drum. Further,
the apparatus and method of the present invention facilitate
the end and side sealing of the carton blan~ upon a rotating
crossbar at a single work station ~Ji thout the necessity of
transferring the carton blank along plural mandrels for each
of the individual end and side sealing operations.
Additionally, the present invention provides a novel
yoke or mandrel conveyor transpor-t which positively supports
and orients the carton blank as it travels through the
pre-form apparatus, filling station, end closure station,
and ejector mechanism. Further~ a unique positive
displacement pump and nozzle assembly utilizing an
internally reciprocating spool to proviae positive
t`
l~l3B~ i
,
.
filling and shut-off is disclosed~ ¦
Description of the Drawings
These and other features of the present invention
will become more apparent upon re~erence to the drawings
wherein: -
Figure 1 is a perspec-tive view oE the apparatus of
the present inven-tion illustrating the spacial relationship
between the plural l~ork Stations (I-VIII) and the
direction o, travel o~ the carton blank as it is
transported through the appara-tus;
Figure lA is a perspective view of the carton formed
by the apparatus and method of the present invention;
Figure 2 is a schema-tic representation of the processes
occùrring at each of the Work Stations (I-VIII) and the
orientation of the carton blank as it travels through the
apparatus of Figure l;
E'igure 3 is a plan view of the carton blank of the
present invention utilized to form the liquid-tight
carton of Figure lA;
Figure 4 is an enlarged perspective view oE a portion
of the carton blank of Figure 3 illustrating the location
of -the tape seal and straw element thereon;
Figure 5 is an enlarged perspective view of the rear
end of the apparatus of the present invention taken about
lines 5-5 of Figure l;
Figure 6 is an enlarged perspective view o~ the carton
blank ~eeder mechanism, heat seal and alignment drum,
straw inserter mechanism, and tape applicator of the
present invention;
Figure 7 is an elevation view, par-tially broken away,
of the carton blank feeder mechanism and heat seal and
alignmen-t drum of Figure 6, depicting the cam an~ pneu~atic
drive mechanism for the heater plate;
35Figure 8 is an enlarged partial perspective view of
the straw inserter mechanism o the present invention;
Figure 8~ i.s an enlarged cross-sectional view taken
about lines 8A~8A of Figure 8 illustrating the method in
which the individual s-traw elements are transEerred from
7~
the stra~ singul2tor into the stra~ feeder m-chanism;
Figure 2B is an ~nlarged perspective view of the
~traw sinsulator of the present invention illustr2ting
the lnternal biasing roller disp~sed therein;
Figure 9 is a sectional view of the stra~ in~erter
mech2nis~ taken. ab~u~ lines 9-9 of ~igure ~ illustrating
the spacial relations~ip between the straw singulator~
s~raw tra~sport channel, and the rotatin~ drum;
~igure 1~ is an enlarged cross-sec.ion21 Vie~J taken
about lir.es 10-lC of Fisure 9 illustratin~ the detailed
operation OL the straw inserter mechanism depositing a
~traw onto the periphe~ ~f the heat seal ~nd alignment
dr~;
Fisure 11 is an enlarged perspective view Or the
tape dispGnser a?~2.atus ~f the~ present invention
illustra.ing t~s plural rotating cutter m~ers znd their
relat~ve orien,ation ti,h the heat seal and alignment dru~;
Figure 12 is a perspective vie; of the lower rotating
çutter m-r~ex of Figure 11 illustrzting the detailed
construction thereof;
Fisure 13 i5 an elevation view of the rotating cutter
me~bers of Figure 11 in a position for initiall~ contacting
the length OL tape;
2~ Fi~u~e 1~ is an elevation vie~7 ~f ~he rotating cutter
me.~ers of ~i~ure 11 in a posi~ion for shearing or cutting
~f the tape length;
Figure 15, on sheet 4, is a partial perspective view of
the heater plate of the heat seal and alignment Qrum illustrating
the detaileQ construction of the undersurface thereof;
~ igurc l is a perspeC~ ive view of the stripper
`~heel mechanisr~ and carton pivot mechani sm of the present
- ~ in~ention;
~ igure 17 is an enlarged elevation view ~f the stripper
35 ~heel mecha-is~ ~f Fi~l~re ~6 illustratin~ the detailed
:~eratic)n the~e~;
,i,~,~,,
..... .
1~Lt3~2'7~i .
6A :
Figure 18 is a perspective view of the carton pivot
mechanism of Figure 16 illus-trating the chain loop transport
mechanism;
Figure 19 is a partial elevation view of the stripper
wheel mechanism and carton pivot mechanism of the present.
\\
`"'""`',
`''`' ~
118~2~5
invention showing the initial transfer of the carton
blank thereon;
Figure 19A is a partial elevation view identical to
Figure 19 bu-t showing ~he final position of the car-ton
blank after transfer from the stripper wheel mechanism; ..
Figure 20 is a perspective view of the pre-feeder
conveyor andshingling conveyor transport of the present
inventlon depicting their relative orientation with the
forming mandrels and wrapping and creasing mechanisms;
Figure 21 is a perspective view showing the position
of a carton blank of the present invention as it enters
theshinyling conveyor transpor-t of Figure 20 and
illustrating the manner in which the carton blanks are
stacked one beneath the other;
p Figure~22 is a perspective view showing the position
of an individual carton hlank as it enters the wrapping
ana creasing mechanism, the blank being disposed about
the forming mandrel;
Figure 23 is a perspective view of the wrapping and
~reasing mechanism of the present invention illustrating
the detailed construction thereof;
Figure 2~ is a perspective view of the wrapping
and creasing mechanism of Figure 23 disposed about the
2~ forming mandrel;
Figure 25 is a cross-sectional view of the wrappiny
and creasing mechanism of the present invention
illus-trating its initial orientation with the forming
mandrel as an individual carton blank enters therein;
Figure 26 is a cross-sectional view of the wrapping
- and creasing mechanism depicting the initial creasing
step of the carton blank about the forming mandrel;
Figure-27 is a cross-sectional-view of the wrapping
and creasing mechanism illustrating the final creasing
step of the carton blank about the forming mandrel;
Figure 28 is a perspective view of the wrapping
and creasing mechanism and forming mandrel oE the
7~
present invention depicting -the mechanism for
transferring -the carton blank to the crossbar mandrel
o-f Figure 30,
Figure 28A is an enlarged cross-sec-tional view of
the upper corner detail of both the forming mandrel oE
Figure 28 and the individual crossbar mandrels of
Figure 30i
Figure 29 is a perspective view of the carton
blank of the present invention sho~ing its configuration
upon being transferred to th crossbar mandrel of
Figure 30;
Figure 30 is a perspective view of -the crossbar
mandrel of the present invention having a car-ton blank
disposed thereon and illustratiny the spacial rela-tionship
betw~en the end folding apparatus, slde sealing anvil,
and end sealiny anvil;
Figure 31 is a perspective view of one end of -the
crossbar mandrel showing the detailed construction of
the forming die rigidly mounted thereto;
Figure 32 is a partial perspective view of the
carton blank of the present invention showing its
configuration upon completion of its travel through
the end folding apparatus of Figure 30;
- 25 Figure 32A is a schematic illustration of the initial
step in the operation of the end folcling apparatus of the
present invention;
Figure 32B is a schematic illustration of the subsequent
step in the operation of the folding apparatus of Figure
32A;
Figure 32C is a schematic illustration of the final
step in -the operation of the folding apparatus of Figure
32A dépicting the sealing tab folded tightly over the end
of the crossbar mandrel;
3$
~L88275
8A
Figure 33 is a perspective vie of the crossbar
mandrel of the presen-t invention having three carton
blanks disposed thereon, illustrating the opera-tion
of the end folding apparatus and the end sealing
apparatus;
Figure 34 is a perspective view of the carton
blank of the present inventionr disposed upon the
10 ~' ~ ' '' . ` , ' ' ''` ' '' ' ,
.
~L~81~12~75
crassbar mandrel, illus-trating the manner in which
the end closure panel is folded over the end of the
crossbar mandrel;
Figure 35 is a perspec-~ive view of the carton
blank rotator mechanism of ~ork Station IV;
Figure 36 is a partial perspective view oE the
carton blank rotator mechanism of Figure 35 illustra-ting
the manner in which the carton blank is transferred
from the crossbar mandrel of Figure 30 into the fixture
of the carton blank rotator mechanism;
Figure 37 is a perspective view oE the carton blank
rotatox mechanism of Figure 35 illustrating the 90~
counterclockwise rotation of the carton blank within
the fix-ture;
Figure 38 is a perspective view of the carton
blank rotator mechanism transferring an individual
carton blank from the fixture into the conveyor
transport of Figure 39;
, 20 Figure 39 is a partial perspective view of the
conveyor transport o:E the present invention illustrating
the detailed construction thereof and the orientation
of the side loader mechanism located adjacent one end
thereof;
Figure 39A is a cross-sectional view -taken about
lines A-A of Figure 39;
Figure 40 is a perspective view of the conveyor
transport and side loader mechanism of Figure 39
illustrating the operation thereof;
Figure 40A is a perspective view of the side loadex
mechanism of Figure 3~ having the conveyor transport
removed for illustration;
- Figure 41 is a cross-sectional view of the
pre form apparatus of Work Station V taken about lines
35 41-41 of Figure 1 schematically aepicting the three
pre-form dies and their relative orien-tation with the
carton blank and the conveyor transport;
3275
Figure 42 is a perspective view of the carton
blank of the present invention showing its configuration
upon completion of the first pre-form die opera-tion
of Fiyure 41;
Figure 43 is a perspective view of the first pre-form
die being positioned over the carton blank of the present
invention;
Figure 44 is a cross-sectional view of the first
pre-form die and its orientation with the carton blank
of the present invention taken about lines 44-44 of
Figure ~3;
Figure 45 is a perspective view of the second
: pre-form die of Figure 41 positioned over the open
end of the carton blank, depicting the detailed
construction thereof;
Figure 4~ is a partial perspective view of the
carton blank of the present invention, illustrating
the spacial rela-tionship between creasing pins of
Figure 45 and the two forward corners thereof;
Figure 46A is a perspective view of the carton
blank of Figure 46 illustrating the configuration of
: the t~o ~on~ard corners thereof after extension of th~
cre~sing pins;
Figure ~7 is a cross-sectional view of the second
pre-Eorm die taken about lines 47-~7 of Figure 45
illustrating the movement of the operator plates thereon;
Figure 48 is a partial perspective vie~ of the
forward corner of the carton blank 9f the present
invention upon completion of the ~econd pre-form
: stage;
Figure ~9 is a perspective view of the third
pre-form die of Figure 41;
~` Figure 50 is a partial perspective view o:E the
anvil of the conveyor transpor-t illustrating the
~eveled top edge and relieved corner theresn,
~L81~2~75
. ~.Figure 51 is a partial perspective view of the
carton blank of the present invention illustrating the
configuration of the sealing tab after the interaction
of the die of Figure 49 with the anvil of Figure 50;
Figure 51A is a perspective view of the carton
blank upon completion of the third pre-form stage operation;
Figure 52 is a cross-sectional view of the lnternal
reciprocating spool nozzle and positive displacement
metering pump of Work Station VI;
Figure 52A is an alternative embodiment filler
nozzle wherein flow metering is -Eacilitated exclusively
by an internal reciprocating spool;
Figure 52B is an enlarged fragmerltary vie~7 o~ the
stationary cap seal utilized in the filler nozzle of
Figure 52A;
Figure 52C is a schematic view of a typical prior art
nozzle design show.ing the liquid flow pattern exiting
therefrom,
r 20 Figure 52D is a schematic view of the internal
reciprocating spool nozzle desi~n OI Figures 52 and 52A
depicting the liquid flow pattern exiting therefrom;
Figure 53 is a schematic view of the operating
and timing mechanism of the present invention connected
to the nozzle and pump assembly of Figure 52;
Figure 54 is a schematic view of the operating
and timing mechanism of Figure 53 shown in a normal
3n - -
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;27~;
i.ntake stroke;
Figure 55 is a schematic view of the operating and
timing mechanism of Figure 53 illustrating the position
of the operating and timing mechanism in a no-fill mode;
Figure 56 is a perspective view of the camming
plate mechanism of Work Station VII illustrating its
in-terrelationships with the conveyor transport;
- Figure S7 is a cross-sectional vie~J of the ca~ing
10 plate of Figure 56 ta}~en abou~ lines 57~57 of Figure 56;
Fiyure 58 is a perspective view of the sealing die
of Work Station VII illustrating the manner in which
the open end of the container is sealed to form a
liquid-tight carton;
Figure 59 is a perspective view of the support
r structure and drive mechanism for the sealing die of
Figure 58;
Figure 60 is a cross-sec-tional view taken a~out
lines 60-60 of Figure 59;
Figure 61 is a perspective view of -the ejector
apparatus of Work Station VIII of the present invention
disposed beneath the conveyor transport adjacent one
end thereof;
Figure 62 is a perspective view o the ejector
apparatus of Figure 51 depicted in its final position
wherein the carton blank is ejected from the conveyor
transport; and
Figure 63 is a plan view of the ejec-tor apparatus
of Figure 61 illustrating the outward travel of the
U-shaped fixture~
e-tai.led Description of the Preferred Embodiment
Overall System Description
Re~erring to Figure l there is shown the apparatus
10 of the present inven-tion which forms a particular
type of container for liquids 12 (shown in Figure lA)
known generally as a Flip and Sip container (a
trademark of Nolex Corporation, the assignee of the
-13-
present invention) and fully disclosed in United States
Patent No. 3,7~9,300, granted July 31, 1973, to Charles W.
Jones.
As shown in Figure 1, the apparatus 10 oE the present
invention includes a base or frame 14 which supports a
plurality of component systems, each of these systems working
in conjunction with each other to produce the sealed container
12 (shown in Figure lA) filled with a liquid substance.
For illustration purposes and to show the spacial
relationship between the component systems of the present
inventio~, the apparatus 10 has been segregated into a series
of Work Stations designated generally by the Numerals I
; through VIII. By progression through these Work Stations I
through VIII~ a carton blank 100 initially loaded onto th
apparatus 10 at Work Station I is formed into a desired con-
figuration, filled and sealed through a series of operations
and is ejected from the apparatus 10 at Work Station ~III.
Referring now to Figures 1 and 2, a brief overview
and a schematic representation of the processes occurring
at each of the Work Stations ~ume~als I through VIII is
illustrated. Note that these figures complement one
another, Figure 2 showing the carton schematically as it
progresses through ~ork Stations I through ~III of Figure 1.
At Work Station I (the Straw and Sealing Tape Applicator
Station~ the carton blanks 100 are loaded upon the apparatus
10 and individually transferred to a rotating drum 1~6.
As the blanks 100 rotate with the drum 146, straw elements
Inot shown) and tape lengths (not shown) are permanently
sealed across apertures 126 formed on the carton blanks 100.
Subsequently, each carton blank 100 is removed from the
rotating drum 1~6 by a stripper wheel apparatus 150 which
~: delivers the carton blank 100 to a rotator or pivot
mechanism 152 for subsequen~ entry into the Work Station II.
27~ii
14
At Work Station II (Carton Blank Wrapping and ~olding
Station), the carton blan]c 100 is transpor-ted transversel~
across -the apparatus 10 and slngularly wrapped and creased
into a square, open tube configuration around a forming
mandrel (no-t shown). Subsequently, the car-ton blank 100
travels to Work Station I~I (the Seam and End Bondin~
Station) by being transferred onto a ro-tating crossbar
mandrel 400 Through a series of operations occurring
at Work Station III, the carton side seam is welded, and
one end o the carton blank 100 is closed and bonded
together to ~orm a liquid-tight seal.
~ t Work Station IV ~Carton Rotator and Conveyor
Transport Station), the carton blank 100 is removed from
the crossbar mandrel ~00, ro-tated 90 about its longitudinal
axist and inserted upon a conveyor transport 550 on which
the carton blank will remain until being ejected from the
apparatus 10. ~hile disposed upon -this conveyor 550, the
carton hlank, supported in a vertical orientation, travels
- ~r 20 to ~ork Station V ~the End Closure Pre-Form Station) wherein,
through a series o~ three discrete operations, the open end
o the carton blank 100 is permanently creased into a
configurati.on suitable ~or the subsequent end sealing
operation.
2S Having the open end of the carton blank 100 properly
creased, the carton blank 100 continues its transport along
the conve~or 550 to ~or]c Station VI (Filler Station) whereln
the carton is filled with a desired liquid. As represen~ed
schema-tically in Figure 2, the filling of the carton blank
100 is accomplished in a two-stage operation b~ a pre-fill
nozzle which supplies the sligh-t majority of the li~uid, and
a topper nozzle which accurately fills the carton blank
to the desired level.with onl~ the latter being adjusted for
the two sizes of cartons produced on the apparatus~
Subsequen-tly, -the carton blank 100, filled with
liquid, travels to Work Station VII (the End Sealing
Station) wherein the open end of the carton blan~ 100
is welded to the square tubular side walls of the
container 100~ ~ith the liquid sealed within the cart~n
bl nk lG~, the carton 1~0 travels to Wor}; Stati~n VIII
(the Carton Ejector Station) wherein an eject~r m-chanism
(not sho~n) removes the carton lDO from the conveyor
trznspDrt 55D and ejects the same ~rom the end of the
a?paratus 10.
~ s ~ill b~-0~2 ~re ap~arent from the follo;~in~
disclosure, the a~aratus 2nd ~-thod of the present
inven.ion provide a hig~ volume pr~ducti~n apparat~s
(ap~r~ximately ~4~ cartons per minute) and additionally
pro~ide significan. sDace, reliability, and consistency
impro~ements over prior art carton f~rming apparatus.
CARTo~ ~L~TT;
Referring now to Fig~lre 3, the~e is sho~!n a carton
blan~ 100 ha~ing a generall~ T-sha?~d configuration from
t~hich the seale~. an~ liquid-tight carton 1~ (sho~.7n in
Fig~re lA) ol the present invention may be formed.
Basically, the carton blank is fo me d ha~ing an elongate
centr~l sec.i~n a~d a pair of end panels integrally attached
adjacer.t on~ end there~f. During the forming of the carton~
the central section is creased intO a sguare ~ubular
3~ coniguration and sealed al~ng ~ne ~f its edges to f~rm
; the side walls ~ the cart~n with the pair of end panels
being subseg~entl~ folded ovex and sealed onto the square
tube ~in a particular manner t~ be de5cribed belowl to
~ro~ide the end walls ~f the cart~n. As Will b2~m~ mDre
3~ ap?3rent, the particular carton blan~ c~nfi~uration yields
a flat t~p container which xeduc~s the am~unt ~f ~aper
~ ~ .
.,
2~
15A
stock used in the con-tainer and increases handling and
crating processes.
The blank 100 is preferably formed of a paperboard
stock having a thickness of approximately fifteen thousandths
of an inch and is coated at least on the outside surface
thereof (which may be assumed to be the surface seen in
Figure 3), and desirably on the inside surface as well,
with a substance that will render the paper impervious to
liquids intended to be contained within khe carton. The
coating substance preferably possesses thermal-responsive
adhesive properties such that liquid-tiyht sealing oE the
component~ of the blank 100 may be accomplished without
the separate application o F conventional adhesive substances
at the time of blank forming and processin~. A thin
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2~;
16
polyethylene film having c~n approximate thic~ness of
1/2 to 1-1/2 mils has been found to include these above
properties and is well suited for use in -the present
invention, especially when the container 12 is used
for potable beverages, such as milk.
As may be s.een, the blank 100 includes an elonyate
central section preferably composed of four eq~lal-sized
segments 102, 104, 106, and 108, which are separated
10 or delineated by indentation or scoring lines 110. As will
be explained in more detail bel~w, these carton segments
102 through 10~ will be folded along the scoring lines 110
to form the side walls of a square tubular configura-tion
for the carton 12 of the present invention.
For~ed inteyral with the carton segment 108 are two
end closure panels 112 and 114 ~Jhich, in the preferred
embodiment, are formed in a general~y square configurati.on,
due to the equal width of the carton segments 102-108.
These end panels 112 and 114 are similar in configuration,
20 except -that the end panel 114 incluaes a pair of sealing
flaps 116 extending outboard of the segment 108 along
opposite edges thereof. Additionally, end panel 112 is
delinated or separated from the carton segment 108 by a
score line 118. It will be recognized that various size
25 cartons may be formed by differing the lengths of the carton
s~gments 102 through 108. It is a unique feature of the
present invention that cartons of two different lengths
(relating to 1/2 pint and 1/3 quart capacity) may be folded,
sealed and filled with only minor adjustments to the
30 apparatus 10~
The carton segmen-ts 102~ 104, and 106 are each
additionally provided with a pair of sealing t~bs 120
formed along their free edges by scoring lines 122. At
the intersection of the scoring lines 110 and-122, the
35 sealing tabs 120 preferably include a scored V~shaped
notch 124 ~hich, as will become more apparent below, aid
in the subsequent l.iquid-tight sealing of the end panels
112 and 11~ to ~he carton segments 102-108.
2~i
The carton blan]c 100 fur-ther includes an elongate
aperture 126 Eormed adjacent the scoxe line 118 and
e~tending partially through the length of the carton
segment 108O As shown in Figure 4, and as will be
e~plained in more detail infra, ~his aperture 126 provides
access to the straw element 220 and is overlayed by a
length of sealing tape 230A which provides a liquid-tight
seal for the carton 100.
Work Station I - Straw and Sealing Tape Applicator
Referring now to Figure 5, the component systems
comprising Work Station I (Straw and Sealing Tape
~pplicator) of the apparatus of the present invention for
forming liquid~containing cartons 12 may be described.
l~ork Station I includes, as major sub-systems, a conveyor
~L: loader 140, a straw inserter 142, a carton blank feeder
mechanism 144, a heat seal and alignment ~rum 146r a tape
dispenser 148, a stripper wheel 150, and a carton blank
~` pivot mechanism 152.
Prior to a detailed description of each of -these
major component sub-sys-tems, a brief overview of the
processes occurring a-t ~ork Station I will aid in the
complete understanding of the apparatus~
Referring to Figure S, the carton blanks 100 are
initially stacked upon the conveyor loader 140 ana travel
horiæontally toward the rotating alignment drum 146~ At
the end of the conveyor loader 140, -the carton blanks
100 are individually raised in a vertical direction and
transferred to the rotating alignment drum 146 by the
carton blank feeaer mechanism 144. Prior to this transfer
~ of the blank 100 onto the drum 146, the straw inserter
: 142 loads a straw element 220 ~as shown in Figure 6) into
a small channel 226 (-shown in Figure 10) formed in the
periphery of the drum 146 such that, as the blank 100 is
transferred to the drum 146, the straw 220 is located
directly under the small aperture 126 ~Figure 4) formed
in the blank 100; i~e., the carton blank 100 ~Figure 4)
11~31~Z~5
-18-
overlays the straw 220.
The straw 220 and carton blank 100 carried by the drum 146
are subsequently rotated past the tape dispenser 148 where a
length of polyethylene coated Mylar substrate tape 230A
(Figure 4) is positioned on the blank 100 over the aperture
126 and straw 220. As the drum 146 continues its counterclock-
wise rotation, a heater plate 254, located within the interior
of the drum 146, cams outwardly and contacts the carton blank
100, thereby bonding the straw 220 to the tape 230 and
concurrently sealing the tape 230 to the carton blank 100 over
the aperture 126.
Subsequently, the blank 100 is removed from the drum 146 by
stripper wheel 150 which deposits the bl~nk 100 in a hori-
zontal plane. The blank 100 is then delivered by the carton
blank pivot mechanism 152 to Work Station II of the apparatus
for subsequent wrapping and folding around a forming mandrel.
Thus, as will become more apparent from the discussion
belowr the carton blank 100, upon completion of its travel
through Work Station I, will include a straw 220 and tape
seal 230A securely sealed across the aperture 126, as shown
in ~igure 4.
Referring again to Figure 5, the detailed construction and
operation of the conveyor loader 140 is illustrated. The
loader 140 preferably includes a pair of elongate conveyor
belts 160 typically formed of rubber having a suitable
coefficient of friction to prevent surface slippage thereon.
These belts 160 are stretched or held taut between two pairs
of pulleys 162. Each pair of pulleys is mounted upon a shaft
164, one of which is connected to a drive mechanism (not shown)
for rotating the pulleys 162 in a counterclockwise direction
(as viewed in Figure 5).
The carton blanks 100 are initially stacked in a row
upon the conveyor belts 160 in an inverted, T-shaped
orientation such that the edge of the end sections 112 and
* Trademark
19
, as well as carton segment 108 (as shown in Figure 3),
contact the V-belts 160. While positioned on the conveyor
belts 160, the vertlcal orientation o~ the stack is
maintaine~ by a pressure pla-te 166 which is spring biased
in a horizontal direc-tion to travel along the length of
the conveyor belts 160 toward the drum 146. As may be
easily recognized, the counterclockwise ro-tation of the
pulley pairs 162 causes the entire stack of carton blanks
100 to move continuously with -the conveyor belts to~7ard the
carton blank feeder mechanism 144.
The loader 1~0 additionally includes a pair of L-shaped
alignment blocks 167 at one end thereof, located above one
oE the pulley pairs 16~. The vertical distance between the
lower sur:Eace of the alignment blocks 167 and the upper
surface of the conveyor belts 160 is spaced to provide a
sligh-t clearance between the edges of the end panels
: 112 and 114 of the car-ton blank 100, and the space bett~een
- the bloc]ss 167 is adjusted to closely receive the sealing
~, 20 tabs 120 of the carton segments 106~ Thus, as the carton
blank stack 100 moves along the tra~eling conveyor belt,
these alignment blocks 167 precisely register each carton
blank 100 upon the conveyor loader 140 for subsequent entry
: into the carton blank feeder mechanism 144. Additionally,
in the preferred embodiment, the outboard alignment block
167 (as viewed f~^om Figure S) is movably mounted in the
direction transverse to the plane of the conveyor 14Q such
that the space between the blocks 167 may be varied. This
variable adjustment accommodates the difFering lengths of
the carton segments 102-108 (Figure 3) when the apparatus
10 is modified to produce both the 1/2 pint and 1/3 quart
capacity cartons :L2~
As the carton blan~ stack 100 moves beneath the
L-shaped alignment blocks 167, each carton blank 100
is sequentially transferred to the heat seal and
alignment drum 1.46 by the carton blank feeder mechanism
144. ~s may be seen in Figure 6, the carton blank feeder
7~i
mechanism 1~ includes an eleva-tor plate 180 and a pineh
roller 18~ which coopera~e to separate a single carton
blan~ 100 from the stack and transfer the blan~ 100 onto
the heat seal and alignment drum 1~6.
The el.evator plate 180 comprises a generally fla-t
plate having a tapered back wall 18~ and a shoulder 186.
formed across its widkh adjacent its leading edge 187.
The shoulder 186 has a small step or recess 188 Eor~ed
adjacent one end thereof, which-is sized to receive one
of the sealing flaps 116 of the carton blank 100 (as shown
in Figure 3). The depth of the shoulder 186 is machined -to
be slightly less than the thickness of a single carton
blan~ 100 such that the edge of only one carton blank may
contact or ride on the shoulder 186 at one time.
Attached to the lower end of the elevator plate 180
is a cammed linkage (not shown) which is connected in a
eonventional manner to the mechanism used for rota-ting the
drum 146. This ca~ed linkage transforms the xotary motion
of the drum 1~6 into reciprocating ver-tical movement o~
the elevator plate 180 as indicated by the arrow 187 in
Figure 6.
The earton blank feeder mechanism 1~4 additionally
ineludes a pinch roller 182 whieh is located above the
elevator plate 180 and in close juxtaposition to the
rotating heat seal and alignment drum 146. ~he outside
diameter of the pinch roller 182 is formed with a redueed
diameter section 190 which extends through approximately
a 180 arc. As will be explained in more de-tail below,
this reduced diameter section 190 permits the elevator
plate 180 to ralse the individual carton blank 100 to a
maximum height before the pi,nch roller 182 transEers the
earton blank 100 to the rota-ting drum 1~6.
The pinch roller 182 is mounted to a shaft 192 which
is connected in a eonventional manner through gears to
the drum 1~6, thereby rotatin~ the pinch roller 182 in a
clockwise direc-tion as sho~7n by the arrow in F.igure 6.
. !~
~8~ 75
21
The rotational speed of the pinch roller 182 is proportional
to the rota-tional speed oE the drum 1~6 such that the
sur:Eace speed of the periphery of the drum 146 and the
5 outside diameter of the pinch roller 182 are equal. The
rotation o~ the pinch roller 182 is synchroniæed wi-th the.
reciproca-ting motion of the elevator plate 180 such that
the reduced diameter sec-tion 190 of the pinch roller 182.is
adjacen-t the periphe:ry of the drum 146 as the car-ton blank
10 100 is raised by the elevator plate 180~ As will be
explained below, this synchroniæed movement be-tween the
pinch roller 182 and the elevator plate 180 pre registers the
carton blank 100 upon the rotating drum 146.
Re:Eerring now to Figure 7, the detailed operation and
15 interrela-tionship be-tween the conveyor loader 1~0, the
carton blank feeder mechanism 14~, and the heat seal and
alignment dxum 1a~6 may be described. As the carton
stack 100 moves along the conveyor loader la~0 past the
alignment blocks 167, the elevator plate 180 recipr~cates
20 downward, whereby the lower edge of the shoulder 186
travels below the lower edge o:E the leading car~on blank
100 indicated by the numeral 200.
In this position, the travel o:E -the conveyor
loader 140 causes -the leading individual carton blank lOOA
25 to be pushed o~ the conveyor loader 1~0 and onto the
shoulder 186 of the elevator plate 180. Since the width
o:~ the shoulder 186 is slightly less than the thickness of
the carton blank lOOA, and the eleva-tor plate reciprocates
closely against the back surface oE the alignment bloc}i
30 167 r on:l.y a single carton blank lOOA is removed :Erom the
s-tack 100 and elevated to~7ard the pinch roller 182. Thus,
as the single blank lOOA is raised, it slides against the
next adjacent blank, which is held stationary by -the
alignmen t blocks 167.
As shown in Figure 7, the elevator plate 1~0 ra~ses
the individual carton blank lOOA be-tween the rotating
drum 1a~6 and -the pinch roller 182 to a height ~herein the
f~!
7~;i
leading eclge of the carton blank lOOA is sligh-tly above the
tangency point between the drum 146 and pinch roller 182
~s previously mentioned and clearly shown in Figure 7,
during this upward travel of the carton blank lOOA and
elevator plate 180, the reduced diarneter section 190 of the
pinch roller 182 faces the periphery of the drum 146 and
is spaced therefrom to provide a small gap 202 into which
the leading edye of the carton blank lOOA may be received~
Thus, as may be recognized, this gap 202 allows the carton
blank lOOA to ride between the rota-ting drum 1~6 and rotating
pinch roller 182, and remain stationary therebetween until
the carton blank lOOA is contacted by the leading edge 20
of the larger diameter portion of the pinch roller 182.
15 The applicant has discovered that by allowing the carton
blank 100 to remain momentarily stationary in this raised
position, the carton blank is pre-registered to within 1/32
of an inch of its proper location on the rotating drum 1~6.
With the carton ~lank lOOA raised to the position
20 illustrated in Figure 7, the cortinued clockwise rotation
of the pinch roller 182 causes -the leading edge 20~ of its
larger diameter portion to contact -the surface of the carton
blank lOOAo Upon contact therewith, the gap 202 is .
significantly narrowed, such that the carton blank lOOA
25 is pinched and propelled upward between the periphery of
the drum 146 and pinch roller 182. Since the relative
surface speeds of the rotating drum 146 and pinch roller
182 are e~ual, the carton blank lOOA is raised uniformly
upward without slippage and removed from the elevator plate
30 180
To facilitate the transfer of the carton blank-IOOa to the
periphery of the drum 1~6, the peripheral surface of the
drum 146 is provided with a series of vacuum orifices 1~7
(shown in Figure 11) preferably arranged in a patterned
array within the area covered by the carton blank lOOA and
connected by a conventional valving and conduit system (not
shown) communicating ~ith a remotely located vacuum source
z~ ~
23
(not shown). These apertures 1~7 ac-t upon the inside
surface o:E the car-ton blan}~ lOOA to effectively m.aintain
the carton blank lOOA pressed against the periphery o:E the
5 drum 146. As may he recoqnized, since the outside diameter
of the drum 146 is much greater than the thickness of the.
carton blank lOOA, the slight curvature of the carton blank
lOOA upon the arum 1~6 is insufficient to cause creasing
or permanent distor-tion of the carton blank ~OOA.
ld To insure the final proper alignment and registration
of the carton blank lOOA upon the drum 1~6, a pair of
registration tabs ~06 are provided alony both outside
ed~es of the drum 146. The peripheral spacing between the
tabs 206 is ad~usted to be slightly greater than the width
15 o:E the end sections 114 and 112, respec-tively, of the
carton blank lOOA ~as shown in Figure 3). Further, the
inside edye of each of the registrati.on -tabs 206 is
preferably provided with a chamfer ~Jhich aids in the
insertion of the end closure panels 11~1 and 112 after
20 transfer of the carton blank lOOA from -the carton blank
feeder mechanism 1~4 to the drum 1~6.
Thus, as the car-ton blank lOOA is pinched between
the roller 182 and drum 146 and applied against the
periphery of the drum 146, these registration tabs 206
25 receive the end closure panels 114 ana 112, respectivelyr
o:E the car-ton blank lOOA at a point adjacen~: the gap 202.
Upon entry of the end closure panels 114 and 112 into the
registxation tabs 206, any IrLinor variances in the location
of the carton hlank 100 upon the drum 1~6 will be eliminated
30 by the tight fit of the end panels lla~ and 112 within the
regis-tration tabs 206 which cause the carton blank to
float along the periphery of the drum la6 into its proper
position. Subsequently, vacuum is applied to the vacuum
orifices 1~7 (shown in Fi~ure 11) to maintain the carton
35 blank 100 in its aligned position upon the periphery oE
the drum 1~6~
Thus, from the above, i-~ may be recognized that the
carton blan]~ feeder mechanism l~L~ effec-tively -txansfers
2~
the carton blan~ 100 from the conveyor loader 140 to an
accurately aligned posi-tion on the heat sealincJ and
alignment drum 1~6.
As previously mentioned, prior to the -transfer of the
carton blank 100 onto the rotating drum 1~6, a plastic
straw element 220 (preferably formed of polyethylene)
must be placed upon the periphery of the drum 1~6, and in
the preferred embodiment is accomplished by a straw
inserter mechanism 1~2
ReEerring jointly to Figures 5 and 8, the straw
inserter 142 is rigidly mounted adjacent the outer
surface of the drum 14~ and maintained in a stationary
position while the dr~n 1~6 rotates in a counterclockwise
direction. The straw inser-ter 1~2 is pre-ferably composed
of a straw storage hopper 222, a separator or singulator
223, and a feeder or transport mechanism 224. A plurality
of straw elements 220 are stored wi-thin the hopper 222
and are oriented such ~hat the length of each stra~
element 220 is parallel to the axis of rotation of the
drum 146. ~t its lower end, the hopper 222 includes an
elongate opening 221 ~shoi~m in Figure 8~ the width of
which is sli~htly greater than the outside diameter of the
straw element 220. As will be explained in more detail
below, this opening 221 permits a single straw element
220 to be transferr~d from the singulator 223 to the
transport or feeder mechanism 22~.
~ s sho~ in Figures ~ and 8A, the singulator 223 is
formed in a cylindrical drum configuration, having an
outer shell 201 which includes a plurality of semi-circular
grGoves 225 symmetri.cally spaced along its outer periphery~
The width of the grooves 225 is preferably formed slightly
greatex than the diameter of the straw element 220 such that
a single straw element 220 may be carried therein.
Disposed within the interior of the shell 201 and
positioned adjacent its lower edge (as shown in Figure 8A)
are a pair of roller members 209 wllich are each mounted for
rotation about a shaEt 211~ The shafts 211 axe
vertically spaced from the a~is of the outer shell 2~1
and e~tend outboard of the simulator 223 being supported
at one end by a pivot arm 203. The roller members 20~
are free to rotate about the shaf-t 211 (in a direction
indicated by the a.rrow in Figure 8A~ while the shaft
211 is spring loaded as by way of springs 205 in a
downward direction to continuously bias the roller
members 209 adjacen-t the lower end of the shell 201.
In the preferred embodiment, the inside diameter of the
shell 201 includes a pair of annular recesses 227s ~7hich
ex-tend part-way into the grooves 225 forming plural
apertures 207. These recesses 227B provide a race or
path which aligns the roller members 209 with the shell
201 while the apertures 207 permits the rollers to enter
subs-tantially within the interior of the grooves 225.
As shown in Figure 3A, by this particular arrangement,
the roller members 209 each selectively contact the portion
of each straw element 220 residing directly above the
apertures 207 formed by the annular recesses 227B thereby
causing the straw elemen-t 220 to be axially pre-stressed
into an oval configuration adjacent the lower end of the
hopper 222. As will be explained in more detail below, this
25 pre-stressing of the straw element 220 is utilized to
provide a self-propelling means for transferring the straw
element 220 into the straw feeder or transport mechanism
224.
Referring to Fi~ure 8, it may be seen that the
30 singulator 223 is mounted as b~ way of a cen-ter web
(not shown) upon a shaft 227 which is journaled to the
walls o:E the hopper 222 for movement in a clockwise
direction as indicated by the arrow in Figure g. The ¦
shaft 227 mounts a ratchet mechanism 229 adjacent one
35 end thereof ~hich is activated by a hydraulic or
pneumatic actuator 231. This hydraulic or pneumatic
7 5
actuator 231 is connected to an ex-ternal pressure source
(not shown) and is rec~ulated by a valve (not sho~,~m) to
periodically ro-tate the shaft 227 and thus the singulator
223 through an angle equal to the spaci.ng between
adjacent grooves 225 formed along its periphery. As will
be recognized, during this periodic rotation, a single
straw element 220 travels toward the opening 221 formed
in the bottom of a hopper 222 for deposition into the
feeder mechanism 224.
Disposed beneath and positioned tangen-t to the
singulator 223 is a feeder mechanism 224 which rotates
on a shaft233a connec-ted in a conventional geared manner
to the drive mechanism (not shown) o:E the rotating heat
seal and alic~nment drum 146. The feeder mechanism 224
preferably includes an enlarged cylindrical end section
\
.
-
235 having a groove 237 formed axially along its periphery.Disposed wi-thin the groove 237 and reciprocable throughout
the leng-th thereof, is an ejector pin 253 which is connected
to a mechanical lin~age (not shown) contained within the
cylindrical head 235 and synchronized with the rotation of
the heat seal and alignment drum 1~6. ~s will be explained
in more detail below, the ejector pin 253 transfers an
individual straw element 220 toward the periphery of the
drum 146 during operation.
An elongate riser 239 is rigidly a-ttached to the shaft
233aand extends from the inboard end of the cylinder Z35
to a position substan-tially benea-th the periphery of the
heat seal and alignment drum 146 (as better shown in
Figure 9). The top surface oE the riser 239 is provided
wi-th a channel 2~1 having a s~uare tubular configuration,
-~he interior cross-sectional area of which is slightly
greater than that of a single straw element 220. As shown
in Figures 8 and 9, this channel member 241 is aligned
20 wi-th the groove 237 formed in the cylindrical end portion
235 such that a straw element 220 may be transferred
a~ially throughout the length of the groove 237 and channel
member 241. In the preferred embodiment, the channeI
member 241 has a sufficient length to acco~nodate three
straw elements 220.
The extreme inward end of the riser 239 ana channel
me~ber 241 is provided with a pair of access slots 243
which extend radially inward toward the shaft233a to a
depth slightly below the lower surface oE the channel
30 member 241. Further, the top ~ortion of the channel
member 241 is removed adjacent these slots 243 which,
as will be recognized below, facilitates the removal
of the str~w element from the channel member 241. ~s best
shown in ~igures g and 10, these slots 243 are aligned
35 with a pair of ca~ming fingers 245 which are rigidly
attached to the frame (not shown) of appara-tus 10 and
juxtapose the periphery of the heat seal and alignment
28
drum 146. These camming finyexs 245 contact the lower
surface of the stra~ element 220 con-tained within the
channel member 241, causing the straw element 220 to be
transfexred to the periphery of the rotating drum 146
as the feeder mechanism 224 .rotates in a clockwise
direc-tion as indicated by the arrow in Fiyure 8.
The periphery o~ the heat seal and alignment drum
146 includes an elongate groove or channel 226 which
extends partially across the periphery of the hub 146
~as indicated by the dotted line in Figure 9). The
depth of this groove 226 is slightly less than the diameter
of the stra~7 element 220 such that, upon .inser-tion o~ the
straw element 220 into the aperture 226, a small portion o~
the diameter of the s-tra~ element 220 protrudes above the
periphery of the drum 146.
In the preferred emhodiment, -the groove 226 is formed
in an insert member 247 which is attached to and resides
~ ~ithin the interior of the periphery of the heat seal and
; 20 alignment drum 146. As shown, a raised portion 251 of
the insert member is flush mounted to the drum 146 and
forms a portion of the outer periphery of the rotating
drum 146~ Additionally, to maintain the stra~ element
220 within the groove 226 until -the carton blan~ 100 is
applied to the drum 146 (in a manner previously described)
a shroud 249 (Figure 103 is provided which is minimally
spaced from the outer periphery of the drum 146 and
extends between the upper end of the camming fingers245
to just below the gap formed bet~een the drum 146 and
pinch roller 182 (Figure 7).
In operation, as the heat seal and alignment drum 146
rotates in a counterclockwise direction (as indicated by
the arrow in Figure 8), the singulator 223 is rotated
through a short distance (in a directiQn indicated by
the arrow thereon), by the actuation of the hydraulic
or pneumatic cylinder 231. This rotation of the singulator
223 causes a single straw element 220A, .initially located
i32~75
29
at approxima-tely a five olclock position upon the
singulato~ 223 (as indicated in Figure 8A), to travel
toward the opening 221 of the hopper 222 to an approximate
six o~clock position. During this rotational travel,
the portion of the stra~7 element 220A residing immediately
above the apertures 207 forrned by the annular recesses
227B, contacts the periphery of the roller members 209
and is tightly pressed or s~ueeze~ against the lower
wall of the hopper 222 by the springs 205. This squeezing
causes the straw element 220A to deform into a pre-stressed
oval configuration represented by the numeral 220B in
Figure 8A.
In s~nchronism~ with the ro-tation of the si.ngulator
223, the feeder mechanism 224 continuously rotates in a
~lockwise direction (as indicated by the arrow in Figure
8A) so thak the groove 237 formed on the cylinder 235 of
~he feeder mechanism 224 aligns or registers wi-th the
opening 221 of the hopper 222 and the groove 225B of the
singulator 223. This alignmen-t, which, due to the
continuous rotation of the feeder mechanism 224, is
maintained for only an instant oE time, causes the single
straw element 220B to e~it the groove 225B of the
singulator 223 (in a direction indicated by the phantom
25 lined arrow in Figure 8A) and enter the groove 237 formed
in the feeder rnechanism 224.
Due to the downward biasing force of the springs 205
as well as the pre stressed oval configuration of the
straw element 220B, and the high memory properties of the
polyethylene straw element ma-terial, it will be recognized
that the transfer be-t~7een the grooves 225B and 237 occurs
almost instantaneously, with the straw element 220s in
effect being self-propelled or shot from the singulator
223 into the groove 237.
Subse~uent to this transfer of the straw elerllent 220B~
the feeder rnechanism 224 continwes its rotation about the
shaft 233 in a clockwise direction as inaicated by the
arrow in Figure ~, so -that, due -to the ~roove 237 being
formed slightly greater than -the diameter of the straw
. t~
.,
~1~8~S~
element 220B, the straw element 220B may return to its
initial uns-tressed cylindrical configuration. During
this rotation, a shroud ~`. substan-tially suxrounding the
pexiphery of the cylindrical portion 235 of the Eeeder
mechanism 224 r maintains -the stra~ element 220 within the
groove 237.
As the groove 237 and s-traw elemen-t 220 rotate to
approximately the nine o'cloc~ position, as viewed in
Figure 8, the ejector pin 253 rapidly travels throughout
the length of -the ~roove 237, thereby causing the stra~7
element 220 contained therein to enter into the channel
member 241. The channel member 241 which, as previously
mentioned, is formed -to accommodate three strat~ elements,
~ 15 has been preloaded wi-th two straw elements 220 during
the previous t~70 reciprocations of the ejec-tor pin 253.
Therefore, this -transfer of the straw element 220 from the
groove 237, advances -the outer-mos-t straw element to reside
adjacent the extreme end of the channel 241.
Subsequently, the continued rota-tion of the feeder
mechanism ~24 causes the leadi.ng edge of the camming
fingers 245 to enter into the slots 243 formed in the
riser 239 (as shown in Figure 10), and contact the lower
surface of the straw element 220. Upon contact with the
fingers 245, due to the continued rotation o~ the feeder
mechanism 224, the straw 220 cams along the concave
upper surface of the camming ~ingers 245 and travels
vertically upward toward the periphery o-E the drum 146.
The rotation oE the drum 146 and the feeder
3~ mechanism 224 are s~nchronized such that~ as the feeder
mechanism 224 rotates past the camming fingers 245,
the groove 226 formed along the periphery of the
drum 146 is aligned ~^lith the channel 241. Thus, con-tinued
rotation of the Eeeder mechanism 224 causes the stra~J
~IL18B275
31
elemen-t 220 contained within the channel 241 to enter
into -the groove 226 formed along the periphery of the
drum 146~ Once inserted in the channel 226, the straw
element 220 is maintained therein by the shroud 249 ~as
shown in Figure 10) which is minimally spaced from the
outer periphery of the drum 146 and extends from the up~er
end of the camming finge.rs 245 to just below the gap
formed between the drum 146 and pinch roller 182.
After the actuation of the feeder pin 253, during which
the single s-traw element 220 is transEerred into the
channel me~ber 2~1, the feeder pin 253 rapidly reciprocates
back to i-ts initial position as shown in Figure 8 so that
the channel 237 i.s free to receive an additional straw
element 220 from the singulator 223, and repeat the cycle
previously described. Thus, from the above, it will be
- recogni2ed that the straw inserter 142 of the present
invention provides a simple yet effective mechanism Eor
transferring a series of single straw elements 220 from
the hopper 222 onto the periphery of the drum 146.
Subsequent to the insertion of the straw element 220
înto the channel 226, the drum 146 continues its counter-
clockwise rotation to the location where the carton blank
100 is transferred onto the hub 146 by the carton blank
feeder mechanism 144 in the manner previously described.
The location of the channel 226 on the periphery of the drum
146 is designed such that, when the carton blank 100 is
transferred onto the drum 146~ the channel 226 and straw
element 220 is disposed beneath the aperture 126 of ~he
carton element 100 as shown in Figure 4 Thus r by -the
operation of the straw inserter 142 and the carton blank
feeder mechanism 144, the carton blan}c 100 and straw
element 220 are t.ransferred onto the drum 146 in a proper
relative orientation for the subsequent tape length heat
bonding and sealing operation.
Continued rotation of the drum 146 causes the straw
element 220 and carton blank 100 to pass under the tape
,. .
dispenser unit 143 wherein a length o:E tape 230A is
deposi-ted over the aperture 126 of the carton blank 100
(as shown in Figure 4)~
Referring to Figure 5, the tape dispenser mechanism
148 includes the following components: a length of tape
230, a pair of tape caps-tans 231 and 232, a tape yuide
233, a back pressure chamber 234, and a supply spool 236.
The supply spool 23~ is rotatably mounted to the housing
238 and stores the length of tape 230 which, in the
preferred embodiment, is formed of a polyethylene coated
Mylar material. As shown, from the supply spool 236,
the -tape 230 is threaded throu~h the tape guiae 233 and
disposed between the two tape capstans 231 and 232. Tn
operation, the capstans 231 and 232 simultaneously contact
the tape length 230, whereby the tape length 230 is cut
and transferred to the carton blank 100 disposed upon
the rotating heat seal and alignment drum 146.
Referring now to Figure 11, the detailed construction
and operation of the tape dispenser 148 r.~ay be descrihed.
As will be recognized, for purposes of illustration, the
supply spool 236 and the vacuum char~er 234 have been
removed from the apparatus in this figure~ As shown,
the -tape capstans 231 and 232 are each mounted on a drive
shaft 235 and 237, respectively, which are connected, as
by a ~ear train, to the drum 146 to rotate in opposed
directions (as indicated by the arrows in Figure 11) in
synchronism with the rotating heat seal and al~gnment
drum 146.
The upper tape capstan 231 includes a substantially
L~shaped housing 239 having a radial]y extending leg 241
The capstan 235 additionally includes a central cavity
243 into which is mounted a pressure plate 245 having
a convex surEace and a knife ed~e asser!~ly 247.
The pressure plate 245 is preferabl.y formed having a
concave outer surface which includes a series of serrations
or a knurl finish thereon~ As better shown in Figure 13,
the pressure plate 245 is mounted within the cavi-ty 243
2~i
33
adjacent the leg 241 of the housing 239 and is xetained
in position b~ a spring 2~6 compressed ~etween the pressure
plate 245 and housing 239. This spring 246 biases the
pressure plate 245 in a radially out~,Jard direction, yet
permits inwarcl movement of the pressure plate 245 in response
to compression forces exerted on the top surface of the
pressure plate 245.
A knife edge assen~ly 247 additionally resides
within the cavi~y 243 and includes an ~-shaped mounting
member 251 onto which a blade 253 is securely mounted.
As shown in Fi.gure 13, the L-shaped mounting member 251
is pivotally attached to the housing 239 by a self-aligning
pin 249 which aligns the blade 253 with the other capstan
~32 during rotation to ensure that the tape 230 is sheared
completely across i-ts width. Further, the mounting member
251 and blade 253 are bi.ased in a counterclockwise
direction against the housing 239 by a pair of springs 255.
As such, the blade 253 is constantly urged against the
pressure plate 245 and aligned with the other caps-tan 232
as the pressure plate reciprocates radially inward and
outward within the cavity 243.
Referring to Figure 12, it may be seen that the lower
tape capstan 232 has a generally semi circular conEiguration
and includes a boss or land 257 which extends radially
outward therefrom. As with the pressure plate 245 of the
upper tape capstan 231, the top surEace of the land 257
is formed in a convex configuration, the radius oE which is
complementary to that of the pressure plate 2~5 of the
upper tape capstan 231. In addition, the land 257 includes
a knife edge 254 adjacent one side thereof which aligns
with the blade 253 of the upper capstan 231 d~ring operation
to shear the tape length 230 in a manner to be described
belo~. The top surEace of the land 257 inclu~es a plurality
o:E apertures 259 extendin~ across the length thereof ~hich
. are connected to an externally located vacuum source (not
shown) ~s will become more apparent from the follotJing
description, the vacuum at these aper-tures 259 holds the
tape length 230 against the land 257 for subsequent
l~ *
,75
3~
deposition upon the periphery of the drum 146.
~s shown in FicJure 11, the tape capstans 231 and
232 are preferably positioned in a subs-tantially vertical
S orientation and are spacec'. from one another such that,
durinc~ their opposecl xota-tion, the convex sur aces o~ the
pressure plate 2~5 and land 257 tangen-tiall~ contact one
another. Additionally, the lower tape capstan 232 is
mounted in close ~ux-taposition to the rotating drum ~6
1~ such that the outer surface of the land section 257 is
minimally spaced Erom the periphery of the rotating drum
1~6 during rotation.
The tape guide 233 is com~osed of a pic-ture fram~-likQ
supPort structure 261 having a pair oE tapered, mating
plates 263 and 26~ which are rigidly mounted along the
bottom surface of the -Erame 261 and pivotall~ mounted
adjacent the median oE the rrame 261, respec-tively. The
support frame 261 is additionally pivotally attached
intermediate its len~th to a bracket 269 which is ricJidly
connected to the frame or housing 23~.
A hydraulic or pneumatic opera-tor 271 a-ttached to
the upper end of the frame 261 is provided to adjust the
orientation oE the plate members 263 and 265 relative the
tape capstans 231 and 232. As will be recoynizedr by
energizin~ the operator 271, the support Erame pivots
in a coun-terclock~ise direction to position the plates
263,265 proximal the two tape capstans 231 and 232
as illustrated in Fi~ure 13.
The lower surface oE the upper plate member 265 is
formed having a shoulaer 267 which extends throucJhout its
width. This shoulder 267 forms, in effect, a one-way
wedge which permits the upper plate 265 to pivat about
its upper pivot axis toward the tape capstans 231 and 232,
yet prevents ny pivo-tal movement of the top plate member
3S 265 in the opposite direc-tion therefrom. Further, the top
pla-te member 265 is constantly urgecl in -the direction away
fxom the capstans 231 ana 232 by a sprinc~ 273 which extencls
from the rear surEace oE -the top pla-te member 265 to the
,~,.
~8~275
rigid support bracket 269. I~i-th the tape length 230
threaded between the pla-ke members 265 and 263, the
do~nward pivotal movement of the pla-te 265 is
cons-trained by the lower plate 265 so -that the tape
leng-th 230 is permitted to travel only in the direction
toward the tape capstans 231 and 232, as indicated by the
arrow in Figure 11.
During the initial star-t-up procedure of the
apparatus 10, -the hydraulic actuator 271 is energized,
thereby pivoting the plate ~.emb~rs 263 and 265 closely
adjacent the tape capstans 231 and 232 to the position
indi.cated in Fi.gure 13. As shown, in this initial
position, the tape length 230 preferably extends
slightly beyond the ends of the plate members 265 and
263 and resides along a plane tangen-t between the tape
capstans 231 and 232.
~s the tape capstans 231 and 232 rotate in their
opposed directions as indicated by the arrows in Figure
20 13, the leaaing edges of the land 257 and the pressure
plate 245 simultaneously contac-t opposite sides of the
tape length 230, thereby tightly pinching the tape length
230 against the knurled top surface of the pressure plate
2~5.
The continued rotation of the tape capstans 231 and
232 causes the tape length 230 to be advanced from the
tape guide 233 across the width of the concave surface
of the land 257. During this ro-tation, the pinching
pressure exerted by the land 257 against the top surface
of the pressure plate 245 causes the pressure p].ate 245
to reciprocate in a radially inward direction, o~ercoming
the opposing force exerted by the biasing spring 2~6.
During this operation, the tape length 230 is advanced
from the tape guide 233 while the pressure plate 245
reciprocates within the cavity 243 of the rotating
member 231.
As shown in Figure 1~, with the continued opposed
rotation of the tape capstans 231 and 232, -the pressure
7~i
36
pl.ate 2~s5 reciprocates radially inward beyoncl the top
edge of the blade 253. Additionally, during this
rotation, a pair of tabs 2~8 which protrude radially
outward from the distal edge o:~ the blade 253 contact
the trailing edge oE the knife edge 25~ causin~ the blade.
253 to pivot slightly backwards against the spring 2550
This slight backwarcls`pivoting aligns the cutting blade
253 with the knife edge 25~ so that the blade 253 shears
the tape length 230 adjacent -the trailing edge o:E the land
section 257 o~ the lower tape capstan 232. The sheared
length ol tape 230A (as shown in Figure 1~) is subsequen-tly
maintained on the outer surface of -the land 257 of the
lower tape capstan 232 during continued rotation of the
tape capstans 231 and 232 by the vacuum applied through
the ~acuum apertures 259 (shown in Figure 12).
The vacuum is maintained during the conti.nued
rotation o~ the capstan 232 ~mtil approximately the
seven o'clock position (as viewed from Figure .L~), at
which point the tape length is proximal the periphery of
the dru;n 1~6 (shown in Figure 11). In this seven o'clock
position, the vacuum to the vacuum ports 259 of the lower
tape capstan 232 is discontinued, so that the vacuum ports
147 located on the periphery of the heat seal and alignme~t
drum 1~6 and acting through the aperture 126 o~ the carton
blank 100 pull the tape length 230A from the surEace of
-the land section 257 tightly against the periphery of the
drum 146.
Referring to Figure ~, the approximate size and
orienta-tion of the tape length 230A upon the carton blank
100 may be seen. As shown, -the tape length 230A is formed
having a leng-th L which is su:Eficient to extend across the
width oE the aperture 126. Additionally~ the ~7idth of the
tape length 230 is sized to extend beyond the encls of the
aperture 126 onto the carton segment 108 and the end
closure panel 112. As will be explainea in more detail
below, this extension of the tape length 230a over the
37
aper-ture 126 is necessary to facilitate the heat sealing
and bondincJ process whlch subsequently occurs upon the
rotatin~ drum 146.
The rotational speed and relative orientation of the
tape capstans 231 and 232 must be precisely synchronized .
with the rotation o:E the heat seal and ali~nment drum 146
to insure tha-t the tape lencJth 230A is deposited over the
aperture 126 of the carton blank 100 upon the peripher~
of the rotatincJ drum 146. Further, it will be recognized
that it is imperative that the vacuum to the ports 259
located upon the land 257 of -the lower tape capstan 232
be discontinued at the proper position to allow the
tape len~th 230A to be transferred onto the periphery
15 oE the drum 146.
In the preferred embodiment, the applicant has found
that by directly cJearing the shaf-ts 235 and 237 of the tape
capstans 231 and 232, respectively, to the drive mechanism
of the rotating drum 146 and additionally utilizing a
sliaer plate valve (not shown) connected to the vacuum
ports 259 to reyulate the applicatlon of vacuum
dependent upon the rotational orientation of the caps~an
232, the precision and repetition necessary to facili-tate
proper operation of the tape dispenser 148 may be obtained~
Further, the applicant has discovered that~ to
maintain the proper orientation of the tape length 230
enterin~ the tape ~uide 233 and to prevent an excess amount
of tape 230 from beincJ dispensed from -the tap2 guide 233,
it is desirable to power advance the tape length 230 from
30 the supply spool 236 to the tape cluide 233. In the preferred
embodiment, this power tape advance is accomplished by a
motor drive (not shown) on the spool 236 which is
controlled by a pair of pressure sensitive switches (not
shown) positioned at different locations within a vacuum
35 chamber 234 (Fi~ure 5). As shown, the vacuum ch~mber 234
is pre:Eerably formed in a rec-tan~ular box~ e confic~uration
havin~ a sealed and opened end, respectively. ~ vacuum
2~7S
38
cluct 277 communica-tes with the vacuum chamber 234
adjacent the sealed encl and is connected to an ex-ternal
vacuum source (no-t shown). Disposed midway be-tween the
sealed and open ends of the vacuum chamber 23~ is a wire
screen or mesh 275 which permits the vacuum to act
therethrough yet prevents the tape length 230 from
entering into the duct 277. The pair of vacuum switches
(not shown) are disposed adjacent the open end o -the
chamber 234 and are horizontal~y spaced from one another
and the mesh 275.
As shown, the -tape length 230 is wrapped around a
spool 279 and inserted into the open end of the vacuum
cham~er23~ in a looped configuration. The vacuum,
acting through the duc-t 277, pulls the tape loop toward
the wire screen 275, causing the vacuum to act upon the
side of the -tape length 230 facing the screen 2-75... ~hus,
it ~lill be recognized that the pressure switches (not
shown) are exposed to vacuum or atmosphere depending upon
~' 20 the location of the tape loop w.ithin -the chamber 23~.
In the preferred embodiment, this alternative exposure
to the vacuum or atmospheric pressure is used to control the
motor drive (not shown) of the spool 236 witn the motor being
actuated when the switch furthest from the screen 275 is
under vacuum and deactivated when the switch closest to
the screen 275 is under atmospheric pressure. Thus, the
amOlmt of tape length 230 available to advancement through
the tape guide 230 is automatically regulated to prevent
the tape length 230 from being over-advanced during the
tape dispensing cycle.
11E18275
39
Additionally, it will be recognized that, due to the
shearing oE the tape length 230A occurring at a point
subs-tantially spaced from the end oE the plate mem~ers
263 and 265 (as sho~m in Figure 14), a short amount of
tape 230B extends beyond the plate members 265 and 263
upon each shearing operation. After shearing, the
tape end 230B is thus in proper position for the repetition
of the tape advancing, shearing, and depositing cycle.
Thus, from the abover it will be recognized that, af-ter
passing beneath the tape dispenser unit 148 oE the present
invention, a length of tape 230A is cut and placed over the
aperture 1~6 and main-tained upon the car-ton blank 100
disposed upon the periphery o the rotating heat seal
and alignmen-t drum 146.
The next process per-Eormed in Station 1 is the heat
sealing and bonding process wherein the straw element 220
is tack bonded to the tape length 230A and the -tape length
230A is concurrently sealed to the carton blank 100 over
the aperture 126. In the preferrea embodiment, this heat
sealing and bonding procedure is accomplished on -the rotating
drum 146 by a novel heater plate apparatus which is stored
in a retra~ted position within -the interior of the drum 146
and intermitently cams outwardly through the periphery of
the drum 146 to contact the carton blank 100.
As shown in Figures 6 and 7, the drum 146 includes
four square-shaped apertures 250 which are spaced
symmetrically around the periphery of the drum 146 ~i.e.S
at ~0 intervals). The leading edge 252 of each of the
apertures 250 is located adjacent the rear alignment tab
206 such thatt the aperture 250 is closely positioned near
the panel segment 108 when the cart-on blan~ 100 is maintained
on the drum 146. Coopera-ting with the aperature 250 is a
I' ,~.
~ o
heater plate 254 pivotally connected to a cam follower 256
hich rides within a cam 255 (illustrated schematically
in Figure 7) and is rigidly mounted within the interior
of the drum 1~6~ A hydraulic or pneumatic actuato.r 257
is additionall~ ~ounted to the cam follower 256 adjacen-t-
one end and extends to the heater plate 254 at a point
located c~bove the heater plate-cam follower pivot. ~s
will become more apparent below, duriny rotation of the
drum 146V the cam follo~7er 256 rides within the stationary
cam 255 thereby extending and retracting the heater.plate
254 through the aperture 250. Upon extension therethrough r
the hydraulic actuator 257 is energized and extended
throuyh a short distance causing the lower surface of the
hea-ter plate 25~ to be pressed firmly down against the
periphery of the drum 1~6.
The heater plate 254 preferably includes a xesistive
hea-ting ele~ent (no-t shown) w'nich electricall~ he~ts the
plate 25~ to a te~.,perature suitable for rapidly tacking
`~ 20 the polyethylene straw element ~20 to -the tape 230~ as
well as bonding -the polyethylene coating on the Mylar -tape
length 230A to the carton blank 100. As shown in Figure 15,
the bot-tom surface 259 o~ the heater plate 25~ inclu~es
a raised boss 261 formed in a rectangular picture
frame-like configuration and a tab member 263 surmounted
within the interior thereof, both oE which are
preferably formed having a smooth face~ The outsiae
dimensions of -the boss 261 are si~ed slightly greater than
the aimensions of the aperture 126 of the carton blank 100
such that when -the heater plate 254 is pressed down upon
the carton blank 100 disposed upon the periphery of the
drum 1~6, the boss 261 and tab 263 contact the peri~leter
of the tape length 230A and a localized area of tape
length located above the straw elemen-t 220, respectively,
as indicated by the sti.ppled lines in Figure 4.
Referring to Figure 7, the cycle of the heater plate
~ 254 w}lich occurs cluring each revolution of the drum 146
; is illustrated. As the individual carton blank lOOA
1,
32~
~ 1
is transferred to the periphery of the drum 146, in the
manner previously described, the heater plate 254A
~indicate~ in phantom lines~ is stored within the interior
of the drum 146 so that it does not interfere with
the carton blank transfer process. As the drum rotates
from a three o'clock position toward the twelve
o'clock position, a cam follower 256 riding wi-thin the
cam 255 e~tends the heater plate 254s radially outward
through an aperture 250 and then slightly for~ard in a
counterclockwise dlrection. While in this extended
position, a pneumatic actuator 257 is energized in a
direction indica-ted by the arrow in Figure 7, thereby
firmly pressing the bottom surface 259 ol the heater
plate 254B against the carton blanX 100. In the preferred
. embodiment~ the cutward reciprocation of the heater
p~ate 254B and direct contact against the carton blank
100 occurs rapidly and is comple-ted at approximately the
: one o'clock position in Figure 7, As previously
mentioned, the heater plate 254 only contacts the car-ton
blank 100 in the localized area of the tape length 230A~
straw el.ement 220, and aperture 126 (as indicated by the
stippled lines in Figure 4) such that the polyethylene
substance coating the remainder of the blank 100 is not
; 25 heated or damaged during this process.
The heater plate 254B remains in contact with the
carton blank 100 for approximately 1/2 xe~olution o the
drum 146 or until the heater plate 254C rotates past the
nine o'clock position as shown in Figure 7~ During this
period, the heater plate 254B, heing at an elevated
temperature due to a resistive heating element therein
(not shown), causes the tape length 230A -to ~e bonded to
a portion of the straw element 220 and concurrently be
sealed to be the ou-ter surface of the carton blan~ 100.
It will be recognized that the temperature of the
heater plate 254 must be maintained at a constant value
~hich is suf~icient to rapidly bond c~na seal the
polyethylene straw element 220 to the polyethylene
coated tape length 230a and carton blank 100, yet be low
enough to prevent vaporization of the polyethylene
material or the melting of the Mylar substrate o the
tape length Z30a. Further, due to the polyethylene stra~
element being substantially thicker than the polye-thylene
coating on the tape length~30a or carton blank 100, and
the insulation effects o~ the card~oard carton blanl~ 100,
the temperature o~ the heater plate as well as the period
o~ time that the heater plate 254 contacts the elements,
must be carefully controlled to en~ure a satisEactory
seal and bond.
Additionally, the applicant has ~ound that, due to
the di~ferent thermal expansion rates o-f the Mylar and
polyethylene materials, -the tape length 230A, i~ preheated,
will wrinkle during -the bonding process~ As such, the
heater plates 25~ must firmly press the tape length
~, 2U 230A against the carton blank 100 and additionally
rapidly seal and bond the elements together~
Thus, it will be recognized tha-t, through the
reciprocating heater plate 254 and raised boss 261 and tab
member 263 o~ the present invention, a rapid, direct
heat and pressure bonding o~ the tape length 230~, straw
element 220, and car-ton blank 100 may be accomplished (in
the preferred embodiment occurring in a time span of
approximately lJ2 of a second) which could not readily
be accomplished b~ the application o~ a remotely located
heating member or preheating o~ the tape length.
Additionally, it should be noted that, although in the
pre~erred embodiment the heater 25~ utilizes a resistive
heater element, alternative heating and bonding processes
which could be adapted to the reciprocating heater plate
25~ (such as ultrasonic ~elding) may be utilized
e~ectively.
~ s the drum 1~6 cont~nues to rotate past the nine
o'clock position r the cam ~ollower 256 and heater plate
~ 3
254C begin kheir re-traction cycle, remo~in~ the heater ~late
254D from the carton blank 100 and retracting it beneath the
aperture 250. As shown, this retraction cycle is complete
when the drum 1~6 rotates to approximately the six o'clock
position. Thus, after completion of one revolution of the
drum 146 (which in the preferrea embodiment occurs in
one second), the heater plate 254 bonds the straw element
220 to the tape length 230~ and concurrently provides a
li~uid-tight seal across the aperture 126 as shown in
Figure 4.
Al-though, for illustration purposes, the operation of
only a single heater plate 254 has been described, it will
be recoc~nized that four heater pla-tes 254 are provided on
~-5 the drum 1~6 which cooperate with four apertures 250, such
-that four carton blan~s 100 are heat sealed and bonded
during a single rotation of the drum 1~6. Further, it
should be noted that since the polyethylene coating is
utili~ea on only one side of the tape length 230A and
the Mylar substrate has a substantially higher melting
`~ point than polye-chylene, the tape length 230A does not
stick or adhere to the lower surface of the heater plate
259 when the heater plate 254 is retracted from the carton
blank 100.
After the heat sealing and bonding process has
occurred~ the carton blank 100 is removed from the rotating
drum 146 and transferred to the carton blank pivot
mechanism 152 by the stripper wheel asse~bly 150.
Re-ferring to Figure 16, the stripper ~Jheel assembly 15~
includes a disc element 262 which is securely mounted to
a rotating shaft 264. In the preferred embodiment, this
shaft 26~ rotates at a speed precisely two times that of
the drum 146 (i.e , 2 revolutions per second) such that
two carton blan]cs 100 may be removed from the drum 146
during each revolution of the disc 262. The outer
periphery 265 of the disc element 262 is located in close
proximity to the periphery of the drum 1~6 (better shown
in Figure 17~ and is separated from the drum 146 by a
r
s
~ 4
small space or gap 266. As will be explained in more
detail helow, this space 266 permits -the carton blank
100 to be removed from the drum 1~6 and ride or be carried
upon the disc 262.
Located generally on one side of the disc 262 and
mounted stationary to the housing ~not shown) is a stripper
plate or shroud ~68 having a concave inner surface 270
which is spaced concentrically around the periphery of
the disc element 262. This concave surface 270 provides
a deflector surface for the car-ton hlank 100 and causes the
carton blank 100 to conform to the shape of the disc 262.
The disc element 262 is additionally provided with
two pairs oE "L"-shaped trans~er ears 272 located on
both surfaces o~ the disc 262 ancl spaced 1~0~ apart from
each other. These ears 272 extend outward from the
surface of the disc 262 in a direction parallel to the
shaft 26~ such- that they may span across the width of the
periphery of the drum 1~6. Each ear 272 is additionally
provided with a pair of tabs 274 having chamfered inner
edges 276 which engage or grip the end closure panels 112
and 11~ of the carton blank 100 (Figure 3) during the
transfer oE the carton blank 100 from the drum 146 to
the disc 262.
The operation of the stripper wheel mechanism 150
: may be easily understood by referring to Figure 16 and
17. The drum 1~6 and disc 262 are illustrated rotating
in opposed directions as indicated by the arrows in
Figure 16. As the rotating drum 1~6 with the carton elemen-t
30 100 thereon approaches the s-tripper wheel mechanism 150
(i,e~, the si~ o'clock position) r the vacuum supply (not
shown) to the vacuum ports 147 (shown in Figure 11~
is discontinued in the near vicini-ty of stripper wheel
: mechanism 150~ This discontinuance of the vacuum from the
35 ports 147 allows the leading edge of the cartcn blank 100
to lift from the surface of the drum 146 or spring in a
downward direction into the space 266 (as shown in Figv.re 17)~
In this position, continued rota-tion of the drum 1~6
along with -the rotation of the disc element 262 pushes
the carton blank 100 into the passayeway formed between
the s-tripper plate or shroud 268 and the periphery of the
disc 262. Duriny this motion, the carton blank 100 cont~cts
the concave surface 270 of the plate 2G8 and bends into an
arcuate confiyuration. As the drum 146 and disc 262
continue their opposed synchronized rotation, the tabs 206
10 of the drum 146 and the ears 272 of the tabs 274 of the
disc 262, confrant each other in a tangential relationship r
so that the tabs 206 and tabs 274 are in a generally parallel
configuration as shown in Figure 17.
In this position, the carton blank 100 releases from
the registry tabs 20G as well as from the periphery of the
drum 146 and is aligned by the tab 274 of the ears 272.
~s may be recoynized, since the tabs 206 and 274 each
include chamfered inside edges, transfer of the carton
element 100 between the tabs 206 ancl 274 occurs smoothly
without hending or deformi.ng the carton blank 100.
Following this transfer of the carton blank 100
between the tabs 206 and 274, continued travel of the
carton blank 100 is provided exclusively by the rotation
of the dise 262 with the edges of the end panels 112 and
25 114 con-tacting the tabs 274 in a similar manner to that
previously described in reference to the rotating drum
146 and with the stripper plate or shroud 268 loosely
holding the carton blank 100 against the disc 262.
Subsequently, as the disc 262 rotates throuc~h approximately
30 a 180 arc, the carton blank 100 exits -the stripper wheel
mechanism 150 adjacent the lower end of the stripper plate
268 and i.s disengaged from the tabs 274 of the ear pairs
272. Thus, the carton blank 100 is deposited with the
straw element 220 facing in a ciownward direction~ upon the
35 horizontal pivot mechanism 152 as shown in Figure 16.
Once the carton blank 100 is disengayed from the ears
272, the disc 262 is free to continue its clock~ise rotation
t ~:
%7~;
~ 6
without impar-tin~ any further motion to the carton blan~
lOQ and travels toward the twelve o'clock position to
another carton blank 100 on the drum lA6. Thus, as may be
recognized, during each 180 rota-tionr the stripper wheel
mechanism 150 transfers a carton hlank 100 Erom the
ro-tating drum 146 by s-tripping or peeling the carton blank
100 off the periphery of the drum 1~6 and dep~siting it
in a horizontal plane for subse~uent transfer to Work
S-tation II.
Subsequent to its removal -from the heat seal and
alignment drum 146 and prior to total disengagement from
the stripper mechanism 150, the carton blank lQ0 ls
transferred to the car-ton blank pivot mechanism 152 which
lS feeds the carton blank 100 into Work Station I~ (the
Mandrel Wrapping and Folding Appara-tus). As shown in
Figures 16 and l.~, the pivot mechanism 152 pre~erably
includes a continuous chain drive loop 280 which extends
between two sprockets 28a and is formed of a plurality of
straight link segments 282 fle~ibly interconnected at
each end. These chain segments 282 and their flexible
interconnections allow the chain 1OGP 280 to follow a
substantially semi-circular path as it travels in the
direction .indicated by the arrows in Figure 1~.
A pair of support plates 271 and 273, preferably
formed of Te-Elon (a registered trademark of E~ I. Du~ont
De Nemours) possessing a concave and convex edge
configuration, respecti.vely, are rigidly mounted inboard
and outboard of the chain loop 280 and form a guide
channel t~hich maintains the semi.-circular orientation oE
the chain loop 280. In the preferred e~bodiment, these
support p].ates 271 and 273 extend slightly vertically
above the chain loop 2~0, thereby formincJ a support
surface upon which the three leading carton blan~
segments 102 through 106 of -the car-ton blank 100 may
rest upon during transport (as shown in Figures 19 and
l9A). Althollgll not shoun for purposes o:E illustra-tion,
it will be recognized tha-t a similar pair of plate
2~7S
47
members is disposed adjacent the lo~er portion of the
chain loop 280 to guide the chain loop 280 on its
return travel.
The chain loop 280 is provided with five pairs of
L shaped channel members 287 (note only two paixs are
shown in Figure 18 for illustra-tion purposes~ ~rhich extend
in a subs-tantially perpendicular orientation thereto, and
ride upon the top surace of ~he plate me~bers 271 and
273. As shown, the channel member pairs 287 are
equidistantly spaced fro~ one another along the length
of the chain loop 280, and oriented to consecutivel~
receive a car-ton blank 100 from the s-tripper mechanism
150 in a manner described below. The height of the vertical -
leg 291 of -these channel member pairs 287 is substan-tially
less than the width of the horizontal leg 293, and includes
a registry tab 295 adjacent both ends -thereof. These tabs
295 are formed in a manner similar to the registry tabs 274
of the stripper ~heel mechanism 150 and are designed to
`r 20 register the carton blank 100 along the edges of the end
closure panels 112 and 114 in a manner previously described.
The space between adjacent channel members o each of
the channel member pairs 287 is sized to be slightl~
greater than the width of the end closure panels 112 and
25 114 o~ the carton blank 100 (as shown in Figure 3), such
that the carton blank 100 may be received therein~
As shown in Figure 18, the chain loop 280 engages
a pair of sprockets 284 which are rigidl~ mounted
~L3L81~3Zb7Si
48
adjacent opposi-te ends of a spli-t drive shaft 2~3. This
shaft 283 engages a differen~ial gear train (no-t shown)
mounted within a differential hcusing 285 which is
dri~en from the main drive system (no-t shown) of the
rota-ting drum 1~6 and ro-ta-tes the sprockets 28~ in
opposed directions as indicated by the a~rows in Figure
18. The rotational. speed of the shaft 283 and thus
the surface speed o:E the chain loop 280 is synchronized
10 with the rotation of the disc 262 of the stripper wheel
mechanism 150, such that, as the carton blank 100 is
deposited in a horizon~al orientation by the stripper
mechanism 150 (as previously described), one of -the channel
member pairs 287 of the chain loop 280 is aligned beneath
the axis of the disc 262 oE the s-tripper wheel mechanism
150 (as shown in Figure 19).
As the car-ton blank 100, carried by the alignment
tabs 27~ of the disc 262, approaches the six o'clock
position, the L-shaped channel member pair 287 disposed
20 on the chain loop 280 simultaneousl.y extends around the
sprockets 28~ to assume the position shown in Figure 19.
In this position, the carton blank segments 10~ through
106 of the carton bl.ank 100 rest upon the support plates
271 and 273 while the frontal edges of the end closure
panels 112 and 114 of the carton blank 100 con-tac-t the
inside surface o-E the registry tabs 295 of the leading
channel member 287. The continued relative movement
- of the disc 262 and the chain loop 280 causes the
registry tab 295 of the trailing channel member 287 to
con-tact the rear edge of the end closure panels 112 and
114, whereby the c~rton blank 100 is completely disengagea
from the tabs 27~ o~ the disc 2~2 with the encl closure
panels 112 and 11~ as well as the trailing carton segment
108 residing exclusively within the pair of channel
members 287 of the chain loop 280 (as shown in Figure l9A)~
Once disposed within the channel pairs 287, the
carton blank 100 is transported in a semi-ci.rcular direction
~L188~75
~ 19
hy t:he continued travel o:E the chain loop 280 (as
indicated by the arrow in Figure 18), and deposi-ted
adjacent the other sproc]cet 284 for insertion into the
5 pre-feeder conveyor 300 (indicated by the phantom lines
in Figure 18). It will be recognized that, as the channel
member pairs 287 approach the other sprocket 284, the
leading carton blank segments 102 through 10~ extena
horizontally keyond the axis of the shaft 273 and are
10 entered between the pre-feeder conveyor 300 and an inclined
plate 30g disposed therebeneath (as shown in Figure 18).
The continued travel of the chain loop 280 causes the
channel member pair 287 to extend downward over the
sprocket 284, whereby the end closure panels 112 and 114
15 of the carton blank 100 are disengaged from the registry
tabs 295 c~nd the channel mernber pairs ~87 trave:l. back to
their initial position along the lower portion of the
chain loop 280. Subsequently, the pre-feeder conveyor
300 engages the end closure panels 112 and 114 of the
20 carton blan}; 100 in a manner to be described below,
thereby transferring the carton blank 100 to the carton
blank wrapping and creasing mechanism at Work Station I:~.
It will be noted that during the operation of the
carton blank pivot mechanism 152, consecutive.cart:on blanks
25 100 are being received from the stripper mechanism 150
between the channel pairs 287 at one end of the chain loop
280, while simultaneously one of the previously entered
carton blanks 100 is being transported toward the pre-feeder
conveyor 300. Similarly, as a channel pair 287 having a
30 carton blank thereon is traveling to~7ard the conveyor 300,
another channel pair 287 is moving back to~Jard the stripper
mechanism 150 along the lower path of the chain loop 280
to subsequently receive another carton blan}; 100 from the
stripper mechanism 150~ Thus, from the above description,
35 it may be easily recogni~ed that, by travel of the carton
:~ blank 100 through Work Station I, a s-traw element and
sealing tape is bonded and sealed to the carton blank 100
Z75
and the carton blank 100 is positioned upon the pre-feeder
conveyor 300 -or subsequent en-try into l~lor} Station Il.
Work Station II - Car-ton Blank Wrappin~ and Fo1ding
. _ ~
~eferring again to Figure 5, the component sys~ems
comprising Work Station II (Carton Wrapping and Folding .
Apparatus~ of the presen-t invention may be described.
Work S-tation II includes a pre-feeder conveyor 300, a
shingling conveyor transport 302, forming mandrels 304, and
a plurality of wrapping and creasing mechanisms 360 (no-t
shown in Figure 5~ which are disposed adjacent each forming
mandrel 304 and positioned beneath the shingling conveyor
transport 302.
Basically, at Work Station II, the individual car-ton
blanks 100 are transported from the pivot mechanism 152 o~
Work Sta-tion I, and registered for entry into the shingling
or stacking conveyor transport 302 by the pre-feeder
conveyor 300. Prior to the en-try of the carton blanks 100
in-to -the shingling conveyor -transport 302 t the carton blanks
: , 20 100 are ar.ranged in groups of four with each car~on blank
100, within the foursome, partially underlayed or shingled
beneath each o-ther by the pre-feeder conveyor such that the
leading edge of each trailing carton blank underlays the
trailing edge of the previously entered carton blank 100
(illustrated in Figure 21~ Additionally, as will become
more apparent below, the leading carton blank 100 of each
foursome group is overlapped upon the preceding foursome
group so that the leading edge of the leading carton blank
overlaps the trailing edge of the last carton blank in the
preceding group~
Disposed in this shingled orientation, the carton
blanks 100 are transported as a foursome group across the
top surface of the forming mandrels 304 by the shingling
conveyor 302. The blanks 100 are then collated and each
loosely wrapped around an individual mandrel 304 and
separated from the conveyor transport 302. Subsequentlys
each of four carton blanks 100 is simultaneously formed
into a square tubular configuration around ~Id conforming
~1~82~
to the shape o the forming mandrels 30~ by the wrapping
and creasing mechanism 360.
After having their side wall sect.ions permanently
creased to form a square tubular configuration, all four
of the carton blan~s 100 are pushed off or ejec-ted from the
forming mandrels 304, and transferred to Work Station III
(Seam and End Closure Bonding Appara-tus). Thus, as will
become more apparent from the disclosure below, upon
completion of their travel through Work Station XI, the
carton blanks 100 are formed into a square tubular
configuration as shown in Figure 29 r with the straw element
220 and tape length 230A sealed thereon.
- Referring now to Figures 20 through 28, the detailed
construction and operation of the apparatus comprising
Work Station II (Carton Blank Wrapping and Folding
Apparatus) will be disclosed. As shown in Figure 20,
the shingling conveyor transport 302 and pre-feeder conveyor
300 both include a conveyor belt, 314 and 301, respectively,
which are moun-t~d at one end in a conventional manner by
two pulley pairs 310 and 311. Both of the pulley p~irs
310 and 311 are carried by a common shaft 312 with the
pulley pairs 310 being rigidly mounted to the shaft 312
and the pulley pair 311 being rotatably mounted upon the
shaft 312 by a suitable bearing 357.
As shown in Figures 1 and 16, the belts 301 of the
pre-feeder conveyor 300 are held taut between the pulleys 311
and an additional pair of pulleys 313 which are r.igidly
mounted to a shaft 317, connected, as by a gear transmission
(not shown), to the main drive system (not shown) of the.
heat seal and alignment drum 146~ Similarly, as shown
in Figure 5, the conveyor belts 314 of the conveyor
transport 302 extend to an additional pair of pulleys 319~
As will be recognized, by such an arrangement, the pre-feeder
conveyor 300 is driven by the shaft 317 (shown in Figure 16
while the shingling conveyor transport 302 is drive~ by the
shaft 312
s
In the preferred e~bodimen-t, the -travel o both the
pre-feeder conveyor 300 and shinglin~ conveyor transport
302 are synchronous, ~ith the speed of the pre-feeaer
S conveyor 300 being faster than that of the shingling
conveyor 302. As will be explained in more detail below,-
this speed differential permits the carton blanks 100
en-tering the pre-feeder conveyor 300 to be arranged in
~roups of four, and shingled or underlayed beneath each
other prior to their engagement with the stacking conveyor
transport 302.
Each of the belts 31~ and 301 of the conveyor
transport 302 and the pre-feeder conveyor 300 are
additionally provided with plura]. pairs of registry tabs
316 and 315, respectively, which extend normal to the
surface of the belts 31~ and 301, and are spaced at
predetermined intervals along the entire length of both
beltsr As previously described in relation to the tabs
206 and 27~ of the rotating drum 146 and disc element 262,
respectively, the space between 2djacent -tabs 316 and 315
of each tab pair is sized to receive the end closure panels
112 and 11~ of the carton blanks 100 (shown in Figure 3)~
Further, as shown, the tabs 316 on the conveyor transport
302 are formed substantially longer than -the tabs 315 on
Z5 the pre-feeder conveyor. As will become more apparent
below, this extended length of the tabs 316 permits the
conveyor transport 302 to engage the carton blanks 100
upon the pre-feeder conveyor 300 in a manner which
compensates for the speed differential between the
conveyors 300 and 302.
As best shown in Figure 20, the pre~feeder conveyor
300 is pre~erably oriented at an angular inclination to
the shingling conveyor 302 and is disposed slightly above
an inclined plate member 309 which extends bet~leen the
carton blank pivo-t mechanism 152 (shown in Fi~ure 1~)
and the shingling conveyor transport 302 (as shown in
Figu.re 20). This inclined plate member 309 is pivotally
mounted adjacent its upper end and communicates with a cam
drive 321 ~hich rotates -to intermitently raise and lower
the plate member 309 about its pivot. The plate member
309, in addition, preferably includes a pair of side
members 309A which extend vertically upward from the ma~n-
planar surface of the member 309~ As will he e~plained in
more detail below, this plate member 309 provides a lower
support for the carton blank 100 traveling along the
pre-feeder conveyor 300 and additionally permits the ~arton
blanks to be arranged into groups of four and partially
underlapped beneath each other prior to their entry into
the shingling conveyor transport 302.
Disposed beneath the plane of the conveyor belts 314
and equidistantly spaced along t~e length o-f the con~eyor
transport 302, are four forming mandrels 30~ which are
rigidly attached to the housing 320 at one end thereo. As
shown, these mandrels 304 are preferably formed having a
generally square cross-section and include a concave channel
322 and a pair of recesses 324 formed along their top and
two side surfaces, respective~y, which extend partially
throuyhout their lenyth, (better shown in Figure 22). The
concave channel 322 receives the straw element 220 attached
to the carton blank 100 during the olding process, whereas
the recess 324 facilitates the ejection or transfer of the
carton blan~ 100 from the mandrel 304.
Cooperating with each mandrel 304 and mounted
adjacent one side thereof, is a separator plate apparatus
designated generally by nume,ral 326 which forms a portion
of the wrapping and creasing mechanism 360~ As shown in
Figure 20, the separator plate apparatus 326 includes a
slider plate 328 havin~ raised side walls 330, and a pair
of rigid elongate stops 332, all of which are mounted to
a sha-t 334. The shaft 334 is supported adjacent one
3~ end thereof by a support arm 336 haviny a bearing aperture
338 the.rethrouyh which allows the sha~t 334 to be rota-ted
therein. ~11 four of the shafts 33~ axe additionally
54
connected at one end thereof to a common drive mechanism
3~0 which may typically include a linkage drive such
that all o:E the shafts 33n can be rotated simul-taneously.
During the operation of ~-~ork Station II, each of
the carton blanks 100 (sho~n in Figure 16) is transported.
from the carton pivot mechanism 152 of l~lork Station ~ by the
pre-feeder conveyor 3no ~rhich receives -the end closure
panels 112 and 11~ of each of the carton blanks 100
between its registrY tabs 315 in a ~nanner previously
described. During this transfer, the car-ton hlan]cs
100 are transported between the lower conveyor loop OL the
pre Eeeder conveyor 300 and -the top surEace of the inclined
plate member 309 ~as sho~n in Figure 20) and -travel to~Jard
the shaft 312 of the shingling conveyor transport 302
As best shown in Figure 21, during this transport,
the end closure panels 112 and 114 ride along the top
surface of the raised side panels ~09a of the plate member
309. As such, the trailing edge of each carton blan}~ 100
r 20 is slightly elevated by the side walls 309A ~hile the
leading edge of the carton blank 100 resides dircctly
against the rnain planar surface of -the plate member 309.
As illustrated in Figure 21, this differing elevation
of the carton blanks 100 upon the inclined plate 309, allows
25 consecutive carton blanks lOOA, lOOB, 100~, and l.OOD of
each foursome to be group oriented along the plate member
309 such that the leading edge o-f the follo~in~ carton
blanks lOOB, lOOC, and lOOD (indicated by the phan-torn lines
referenced by numerals 3~4B, 3~4C, and 34aD, respectively)
30 lies beneath the trailing edge of the preceding carton
blanks lOOA, lOOB, and lOOC. As such, consecutive carton
blanks 100 are underlayed or shingled alon~ the inclined
plate member 309 for subsequent entry into the shingling
conveyor transport 302.
This shingling along the inclined member 309 permits
consecu-tive carton blanks lOOA, 100B, lOOC, and 100~ to be
wrapped around an individual forming mandrel 304, even
though the mandrels 30~ axe spacecl closer to one anothex
than the leng~h of the blanks 100. Further, this
arrangemen t permits the compact arrangement of the mandrels
304 and the succeeding equipment stages, and is an
important factor in permitting the present apparatus to
occupy very limited floor space.
In addition to the shingling procedure, the inclined
plate member 309 (as previously mentioned) arranges the
10 incoming carton blanks 100 in-to groups oE four for
subsequent travel across the four forming mandrels 304.
In the preferred embodiment, this grouping procedure is
provided by the upward pivoting (in a coun tercloc~ Jise
direction as viewed in Figure 21) of the plate member 309
15 caused by the rotation oE the cam 321.
In operation, as every four-th carton blank 100
travels do~m the inclined plate member 309 toward the
conveyor transpor-t 302, the lobe of the cam 321 causes the
plate member to pivo-t upward. This upward pivoting o E
20 the plate member 309 causes the leading edge 344 of ever~
fourth carton blank 100 to be disposed above the trailing
edge of the preceding carton blank (i.e., overlapped upon
the other foursome group) upon the inclined plate` member
309. Subsequentl~ r the cam 321 continues its ro-tation,
25 so that the plate member 309 is again disposed in its
lower, normal operating position.
As such, the next three entering carton blanks 100
are underlayed in the manner previously described, wherein
the frontal edge 344 of each carton blank 100 lies beneath
30 the trailing edge of the preceding carton hlank upon the
plate member 309. As will be explained in more detail
infra, this particular foursome grouping of the carton
blanks 100 permi ts the fixst four carton blanks lOOA through
~OOD to be creased into a square tubular configuration
35 about the forming mandrels 304 while a second group of
four carton blanks 100 are simultaneously transported by
the shingling transport conveyor 3û2 toward the individual
3275
56
forming mandrels 30~. Hence, the creasing and forming
cycles of the apparatus are superimposed with -the
transport and collating cycles oE the apparatus, as
will become more apparent infra.
During the shingling procedure upon the inclined
plate member 309, the registry tabs 316 of the shing~in~
conveyor transport 302 begin receiving the end closure
panels 112 and 11~ of the consecutive carton blanks lOOA
throu~h 100D. Due to the pre-feeder conveyor 300 transporting
the carton blanks 100 at a speed faster than travel of the
conveyor transport 302, it is necessary to avoid
accumula-tion and cloggincJ of the carton blanks 100 upon the
inclined plate 309. Thus, the conveyor transport 30~ must
remove the consecutive carton blanks lOOA throu~h lOOD
from the inclined plate member 309 at a speed greater than
the actual traveling speed of the conve~or transpor-t 30~.
In the preferred embodiment, this increased removal speed
on the inclined plate ~ember 309 is provided by the
increased len~th and radial spaciny of the registry tabs
316 of the conveyor transport 302 engaging the end
panels 112 and 11~ of the carton blan~s 100.
As will be recognized, by engaying the carton blanks
lOOA through lOOD at a point adjacent the extreme outer
radial end of the registry tabs 316, the effective diameter
of the pulley pairs 310 is increased and thus the surface
speed of travel about the pulleys 310 is increased. In the
preferred embodiment, the length of the tabs 316 (and thus
their radial spacing~ is formed such thatr upon engagemen~
with the carton blanks lOOA through lOOD, the effective
diameter of the pulleys 310 in conjunction with the rotation
of the shaft 312 exceeds the speed of travel of the
pre-feeder conveyor 300. Thusl by such an arrangement/
consecutive carton blanks lOOA through lOOD are rapidly
stripped from the pre-feeder con~eyor 300 at a speed equal
to the speed of the pre-feeder conveyor 300 and subsequently
transported hori~ontally at a slower speed by the transport
conveyor 302 toward the forming mandrels 30~
,t' ~,~
~8~1Z7~
Since the width across the raised edges 330 of the
slider plate 328 is slightly less than the length of the
carton seyments 102 through 108, of the car-ton blank 100
(shown in Figure 3) during this -transport by the shingling
conveyor 302 toward the formi.ng mandrels, the undersurface
of the carton blanks 100 rest upon and are supported by
the raisea edges 330 of the slider pla-tes 328. As
such, consecutive car-ton blanks lOOA, lOOB, lOOC, and
lOOD upon the conveyor 302 may travel unrestricted
across all four of the forming mandrels 304.
As the leading edges 344 of each consecutive carton
blank lOOA, lOOB, lOOC, and lOOD, carried by the conveyor
302 (Figure 21), approachetheir respective formi.ng mandrels
30~}, the drive mechanism 340 of the ~rapping and creasing
mechanisrn 360 is momentarily activated, causing each-shaft
334 to rotate through a short arc in a cloc]cwise direct.ion~
- This short arcuate rotation causes the xigid stops ~32
and the slider plates 328 to pivot about the shafts 334
and raise vertically upward along their leading edges.
The carton blanks lying directly above the slider plates
328 (such as lOOA shown in Figure 21) during activation
will be slightly lifted, while the leading edge 344B of
: the following carton blank (such as lOOB shown in Figure
21) is deflected do~nward by the plate 328 to travel
- beneath -the slider plate 328~ As will be recognized,
the fifth carton blank which was previously overlayed
upon the previous carton blank lOOD by the pivoting
of the inclined plate ~.ember 309, will additionally
be slightly lifted during this pivoting of slider plate 328
such that the fifth carton blank 100 will not entex the
creasing mechanism 360 at this time.
After entry of the leading edge 344 beneath the slider
plate 328, the drive mechanism 340 is deacti~ated such
that the slider plate 328 and the rigid stops 332 pivot
back to their lowered position (i.e., the position indicated
in Figure 20)v Thus, the activation and deactivation o
.
58
the separator plate apparatus 326 effectively separates
or collates the individual carton blanks lOOA, lOOB, :LOOC,
and lOOD ad-jacent each *ormin~ mandrel 304. Further,
since the slider plates 328 are returned to their initial
planar orientation, the subsequent group of four carton
blanks 100 may be transported in the same manner by the
shingling conve~or 302 toward the respective forming mandrels
30~.
Subsequent to the activation ancl deactivation of the
separator plate apparatus 326, the end closure panels 112
and 114 of the c~rton blank 100 are still engaged with the
conveyor transport 302 such that each of the carton blanks
lOOA, lOOB, lOOC, lOOD continue their horizontal -travel
lS beneath the slider plates 328 whereby the leading edge 344
of the carton blanX 100 contacts the creasing mechanism
360 as shown in Figures 22 and 23~
The cxeasiny mechanism 360 includes a hinged member
362 having a reciprocating vertical wall 364 and an L-shaped
pivoting, clamping jaw 366. As clearly shown in Figures 23
and ~4, the vertical wall 364 is rigidly mounted to an
elonga-te sleeve member 368 which is clamped at one end
into a support rail 372. The sleeve member 368 suppoxts a
rotatable shaft 370 ~7hich extends beyond both ends thereof
and includes an end cap 374 which is securely mounted t~
the shaft 370~
The L-shaped clamping jaw 366 is rigiclly connected to
thi.s end cap 374 such that, as the shaft 370 is rotated
in a clockwise direction, the jaw member 366 rotates towara
the vertical wall 364. ~s will be~ome more apparent, -this
rotation of the jaw member 366 toward the vertical wall 364
imparts a permanent crease or fold to the carton blank 100,
thereby formin~ the carton blank 100 into a square tube
con:Ei~uration. The inside surfaces of the vertical wall
364 and the L-shaped clampiny jaw 366 are each provided
wi.th a pair of spring pla-tes 378 preferabl~ formed from
Teflon (a r.e~istered trademark of E~ I. DuPont de Numour)
%~
59
~hich effectivel~ presses the carton blank 100 a~ainst the
mandrel 304 duri.ng the folding process. Additionall~, a
deElector ~inger 279 is provided which is rigidly attached
-to the vertical wall 3~ and extencls in an angular segmented
arcuate manner between the spring plates 378 of the vertical
clam~ing ~aws 36~ and 366, respectively.
~ s shown in Figure 22, the creasi.ng mechanism 360
is positioned below the separator plate apparatus 32~
and disposed adjacent the side and bottom surfaces of the
forming mandrel 304. In this position, -the creasing
mechanism 360 ~orms a barrier to deflect the horizontal
travel of the carton blank 100 belo~ the slicler plate
and is free to operate wi-thou-t interference from the
separator plate apparatus 326 and shingling conveyor
transport 302.
The operation of the creasing mechanism 360 is
illustrated in Figures 22-27. As previously mentioned,
during actuation of the separator plate apparatus 326,
~ the leading edge of the carton blan~ 100 passes beneath
the slider plate 323. After further movement caused by
the conveyor belts 314, the leading edge 344 of the
blank 100 contacts the deflec-tor finger 279 disposed on
the inside surface of the ~ertical wall 364 of the
creasing mechanism 360 (better shown in Fiyure 23).
This contact with the deflector finger 279 de:Elects the
leading edge 344 of the carton blank 100 in a do~nward
direction, and with the continued horizontal transport
of the car-ton blank 100 by the shingling con~eyor transport
302, causes the elongate section of the carton blank 100
(formed by the segments 102 108) to cam against the finger
279 to loosely wrap around the forming mandrel 304, as
shown in Figure 2S.
Duriny this same horizontal transport, the leading
edge of the end closure panels 112 and 114 of the carton
blank 100 approach the forming mandrel 304, ancl contact
the base of the elongate stops 332 oE the separator plate
. .
apparatus 326, Since the ends of the stop 332 are
ben-t in an up~ard inclination, the end closure panels 112
and 114 slide beneath the lower sur:Eace of the stops
332, bu-t above the top su.rface of the forming mandxel 304.
Continued horizontal travel of the carton blank 100 by the
shingling conveyor transport 302 causes the leading edge
of the end closure panels 112 and 114 to contact or abut
the shoulder 380 at the base of the stops 332,
This direct abutment with the shoulder 380 effectively
stops the horizon-tal travel of the carton blan~ 100
on the shingling conveyor t.ranspor-t 302 and registers the
carton blank 100 on the mandrel 304 such that the end
closure panels 112 and 114 and the carton segment 108
(as shown in Figure 3) lie exclusively on the top surEace
of -the mandrel 304 and the straw element 220 is disposed
within the concave channel 322.
It will be recognized that during the entry of the
carton blank 100 into the creasing mechanism 360 beneath
~0 the stop 332, -the carton blank 100 is con-tinuously
being pulled in a downward direction from the conveyor
transpor-t 302 by the stop 332. This pulling causes the
end closure panels 112 and 114 during the wrapping pxocess
to slowly slide down the length of the registry tabs 316
away from the belts 314 so that the panels 112,114 engage
the tabs adjacent their lo~ler end. Referring to Figure 207
the frontal edge of the tabs 316 is preferably formed having
a beveled or angular configuration which permit the carton
blank 100 to readily be disenga.ged from the conveyor
transport 302 upon confronting a substantial resistance to
movemen-t. As such, upon abutment with the shoulder 380,
the increased resistance to the horizontal travel of -the
carton elernent 100 along the conveyor transport 302 causes
the registry tabs 316 to comple-tely disengage from the end
35 panels 112 and 114 and slide harmlessly over the trailing
edge of the carton blank 100. In this manner, the carton
blank 100 is maintained upon the forming mandrel 304
f ~;
Z'75
61
and is disengaged from the conveyor transport 302 without
damaginy or permallently creasing the end closure panels 112
and 114 of -the carton blank 100.
Upon disengagement of -the carton blank 100 :Erom the
conveyor transport 302, the creasing mechanism 360
is ac-tivated to begin the carton folding or creasing
process~ The progression of operations perfo.rmed by the
creasing mechanism 360.1s illustrated schematically in
Figures 25 through 27.
In its initial position (Fic3ure 25~, the creasing
mechanism 360 partially surrounds the forrning mandrel 304,
and earries the car-ton blank 100 adjacent the deflector
finger 279 along its inside surfaces. As shown in
Figures 25 -through 27, each of the Eorming mandrels 304
is preferably formed having a slightly inclined kop
surface and includes a small blocking memher 381 extendînc3
a shor-t distance above its top surface and rigidly mounted
adjacent one side. As ~7ill be recognized due to this short
20 pro-trusion above the top surface of the m~ndrel 304, the
carton blank 100 is free to s:Lide over the blocklng member
381 during the above-described wrapping process and reside
slightly beyond the blocking member 381 as depicted in
Figures 25 through 27. As such, the trailing edge of the
carton blank 100 la~s flat upon the slightly inclined -top
sur~ace of the forming mandrel 304 and is prevented from
movement laterally away from the creasing mechanism 360
by the blocking member 381.
Subsequently, the entire creasing mechanism 360 is
reciprocated toward and abutted against the side surface
of the forming mandrel 304 (shown in Figure 26) hy the
transverse movement of the rail 372 as indicated by the arrow
in Fic,~ure 23. By this movement, a corner 382 ~shown in
Figure 26) is permanently formed or creased into the carton
blank 100 along the upper sur:Eace o:E the mandrel 30~ with
the stop men~er 381 preventing the carton blank 100 from
slidincf across the top of the mandrel 304. The formation
2~
62
of this corner 382 is aided by the indentation or scoring
line 110 registered along the edge of the mandrels 304
and formed on the carton blank 100 (as shown in Figure 3)
which significantly reduces the resistance to folding.
With the vertical wall 364 of the creasing mechanism
360 remaining in its abutted relationship with -the mandrel
304 (as shown in Figure 26), the L-shaped ja~7 member 366 is
rotated in a clockwise direction whereby the spring plate
378 urges the remaining segments (102-106) of the
carton blank 100 against the forming mandrel 304 (shown
in Figure 27)
In the preferred embodiment, the ~ovement of the
L-shaped jaw member 366 is accomplished by the rapid
rotation of the shaft 370 through a short arc. Upon
closing, the jaw member 366 permanently creases the carton
blank 100 adjacent the lower edges of the carton blank 100
(as shown in Figure 27) thereby forming corners 384 and
386. As previously mentioned in relation to the corner
382, the formation of these edges 384 and 386 occurs at
the scoring lines 110 formed along the carton blank 100.
Since the spring clips 378 contact the carton blank
100 adjacent the corners of the forming mandrel 304, during
closure of the jaw member 366, the carton member 100 is
moderately stretched against the flats of the mandrel 304
to eliminate the possibility of sagging of the carton blank
intermediate of -the edges 384 and 386. Further, during
closing of the jaw member 366, the deflector fingers 279
extend through the open slot 281 (shown in Figure 23)
formed in the jaw member 366 to extend beneath the jaw
member 366 as shown in Figure 27. As such~ the carton
~lank 100 is tightly creased about the mandrel without
any interference from the deflector finger 279 Thus,
as may be recognized, by the dual movemen-t of the creasing
mechanism 360, firs-t toward the mandrel 304/ and then upward
against the bottom and side surface of the mandrel 304,
the carton blank 100 is permanently folded into a square
tubular configuration.
2~S
63
~fter the creasing mechanism 360 has permanen-tly
folded the carton blank 100 around the mandrel 304, the
carton blanl; 100 must be removed from the forming mandrel
304 and inser-ted upon the crossbar mandrel 400 (as shown
in Figure 30) which forms part of Work Station I~ Seam
and End Bonding Station). However, prior to this transfeic
of the carton blank 100 into Work Station III, the sealing
tab 120 (as sho~m in Figure 27) which e~tends above the
top surface of the n~lndrel 304 mus-t be folded over and
permanen tly creased upon the -top surface of the mandrel
304. Additionally, this sealing tab 120 must be folded
over in a manner so as to be positioned beneath the lower
surface of the carton segment 108 (i.e., the carton
segmen-t 108 overlays the sealing tab 120).
In the preferred embodimen-t~ this folding of the
sealing tab 1~0 is accomplished in a simple yet effective
manner and occurs during the transfer of the carton blank
100 from the forming mandrel 304 to Work Station III.
Referring to Figure 24, the apparatus for bending or folding
~.r ' over the sealing tab 120 and for transferring the carton
; blank 100 from the forming mandrel 304 to Work Station III
is shown~ ~or purposes of illustration, it will be noted
that, in Figure 24, the carton blank 100 has been removed
from between the forming mandrel 304 and -the creasing
mechanism 360. ~s shown, the vertical wall 364 and one ~f
the legs of the L~shaped jaw 366 of the creasing mechanism
360 include a tab 388 at one end thereof, which extends
inwardly toward the side surfaces of the forming mandrel 304O
As may be recognized, these tabs : ride within the recess
channels 324 formed along both side surfaces of the s~andrel
30~ whereby the creasing mechanism 360 may slide foxward
along the length of the mandrel 304.
~isposed adjacent one end of the forming mandrel 304
35 and closely positioned to the top surface thereof is a
folding block 339 which is rigidly mounted to the housing
~not shown)~ The front edge of the block 390 is pxovided
38Z7S
64
with an enlargecl radius 399 c~2d is inwardly tapered to
provide an entry camminy surface, whereas the side wall
392 is beveled so that only a reduced thicXness of the
block 3~9 extends across the width at the top surface
of the forming mandrel 304. As will be explained r
in more detail below, positioned in such a manner the
block 389 directly contacts the sealing -tab 120, but only
s]igh-tly liEts the carton segment 108 during transfer of
the carton segment 100 from the forming mandrel 304 to Work
Station III.
The sealing tab folding operation and the transfer of
the carton blank 100 from the mandrel 304 to Work Station
III may now be described. With the creasing mechanism 360
]-5 maintained in its closed position and the carton blank 100
formed into a substan-tially square tubul~r con-fiyuration as
sho~n in Fi~ure 27, the tabs 388 of the creasing mechanism
360 contact the rear edge of the carton blank 100. The
entire creasing mechanism 360 then reciprocates fol~ard or
slides along the length of the forming mandrel 304 toward
Work Station III. In the preferred embodiment, this sliding
movement is accomplished by the travel of the rail 372 in a
direction indicated by the arrow in Figure 23. However,
othex embodiments wherein only the jaw members 364 and 366
travel along the mandrel 304 may be utili~ed.
As this sliding movement is initiated, the carton
blank 100 passes beneath the stops 332 (as shown
in Figure 20~ and is thereby released from the biasing
force of the stops 332 which previously held the end
closure panels 114 and 112 and the carton segment 108
against the inclined top sur~ace of the mandrel 304.
Due to the subtly inclined top surface of the
mandrel 304 as well as the moderate memory properties
of ~he carton blank 100, during this sliding movement
and upon release from the stops 332, the end closure
panels 114 and 112 and the carton segment 108 tend to
sliyh-tly spring upward off the top surface of the mandrel
7~
304 to lie in an inclined orientation. This inclined
orien-tation aids in the trans:Eer process and additionally
in the seali.ng tab fold-over process b~ allowing the end
closure panels 114 and 112 and the carton segment 108 to
slide past the folding block 389 whi.le the sealing tab 12D
is forced beneath the block 389. Thus, during the forward
travel of the car-ton blank 100 along the mandrel 304,
the end panels 114 and 112 and the carton segment 108
harmlessl~ ride against the upper beveled edge 392 of
the block 389 and pass beyond the block 389. However,
the sealing tab 120 directly abuts the camming eclge 390
of the block 389 and is -thereby bent in a downward
direction toward the top surface of the mandrel 304.
As best shown in Fiyure 28~, the upper left corner
of the mandrels 304 (as well as the mandrels 402 of the
crossbar mandrel 400 of Figure 30) are provided with a
small notch 383, the depth of which is sized slightly
greater than the thic~ness of carton blank 100. The notch
383 prefe~ably extend partially across the top surface of
the mandrels 304 through a length slightl~ greater than
the width of the sealing tab 120. As such, the notch or
po~ket 383 is adapted to receive the sealing tab 120 during
-the fold-over process.
It will be recognized that the fold-over process of
the tab 120 is aided b~ the spring plate 378 which maintains
-the carton blank 100 tigh-tly against the side surface of
the mandrel 304 and the scoxing line 110 (as sho~n in
Figure 5) which weakens the carton blank 100 at a point
adjacent -the edge of the forming mandrel 304. As such,
during the transfer of the carton blank 100 onto the
crossbar mandrel gO0 (of Work Station III), the sealing
tab 120 is bent over and forced be-tween the bot-tom surEace
of the block 389 and the top surface of the Eorming manclrel
35 304 to reside with the notch 383 (as shown in Figure 28A).
Referring to Figure 28, the completion of the transfer
of the carton blank 100 from the forming mandrel 30~ onto
the crossbar mandrel 400 (of Work Sta-tion III) is i
illustrated. As may be seen, the forming mandrel 304 and
66
the crossbar mandrel 400 are aligned in an end-for-end
orientation such that, as the car-ton blank 100 is pushed
off the end oE the forming mandrel 304, it is inserted
onto the crossbar mandrel 400. Aaditionally, both ~he
mandrels 304 and individual mandrels 402 oF the crossbar -
mandrel ~00 include a concave channel 322 and 422 which
receives the straw element 220 during the forming and
transfer pro~esses, respectively.
Upon completion of the transfer of the carton blank
100 to the crossbar mandrel 400 (of Work Station III), the
sealing tab 120 ~indicated in phantom lines) contacts
the top surace of the crossbar mandrel 400 and lies
beneath the carton segment 108 of the carton blank 100.
Thus, from the above description, it will be recognized
that, upon completion of its travel through Work Station
II, the carton blank 100 is permanently creased or folded
into a s~uare tubular configuration, having its sealing
tab 120 placed beneath the lower surface of the caaton
, 20 segment 108 as shown in Figure 29, and aclditionally has
been transferred to the crossbar mandrel 400 of Work
Station III.
Following this -transfer of the carton blanks 100
to the crossbar mandrel 400, the rail 372 reciprocates
back to its initial position and the creasing mechanism
3~0 returns to its initial position adjacent the
forming mandrels 304 (as indicated in Figure 22) and is
disposed to receive the subsequent group of four carton
blanks 100 which were simultaneously being transported
by the stacking conveyor 302 during the creasing process.
For illustration purposes, the description as to the
operations occurring at Work Station II has been presented
in relation to a single carton blank 100 being formed
around a single mandrel 304. EIowever, it will be
recognized that the same procedure described for the single
carton blank 100 occurs si.multaneously at the other three
forming mandrels 304. ~ddi.tionally; it will be recognized
that, although in the preferred embodiment, our mandrels
67
are utilized at this station, fewer or additional forming
mandrels 304 wit~ their respective ~olding and creasing
mechanisms 360 may be utilized ana the pivoting oE the plate
member modified to group the carton blanXs accordingly,
without departing from the spirit oE this invention.
~ork Statlon III - Seam and End ~ondinq Apparatus
Subsequent to the previously described transfer of the
carton blank 100 from the forming mandrel 304, the carton
blank 100 is subjected to a series of operations which occur
at Work Station III wherein the carton blank 100 is
permanentl~ sealed along one edge to maintain the square
tubular configuration and one of the end closure panels
112 is bonded to the carton blank 100 to provide a lic~uid-
tight seal. In the preferred embodiment/ all o~ the
processes occurring at ~ork Station III are performed
on the crossbar mandrel 400 (as shown in Figure 30) thereby
eliminating the complex transfer systems associated in
the prior art devices.
~, 20 Basically, a-t Work Station III the carton blan~ 100
is initially sealed by the side sealin~ apparatus 430 along
the previously overlapped edge at the junction 120,108,
formed duxing the wrapping process in Woxk Station II
. described above. Subsec~uently, the carton bla~k 100 is
25 moved radially outward along the individual mandrel 402
o~ the crossbar mandrel 400 such that the sealing tabs 120
formed along the edge of the carton blank 100 extend
partiall~ beyond the end of the mandrel 402. In this
position, the sealing tabs 120 are contacted by a folding
30 apparatus 440 which folds the sealing tabs 120 tightly
against the end of the mandrel 402.
Subse~uently, the crossbar mandrel ~00, with the
carton blank 100 thereon~ is rotated upward through a
90 arc. During this rotation~ the end closure panel
35 112 contac-ts a roller 446 which bencls the end closure
panel 112 over the end of the individual mandrel ~02~ At
the end of the 90 rotation, the individual mandrel 402
~82~5
68
extends in a ver-tical orientation wherein an ultrasonic
sealing die or horn 450 i.s p.ressed over the end of the
carton blank 100 and mandrel 402 to seal the end closure
panel 112 to the sealing tabs 120.
After the sealing of the end of the ca:rton blank
100, the crossbar mandrel. 400 rotates through an additional
90 arc to align the carton blank lOa for removal from the
individual mandrel 402 and entry into Work S-tation IV
~the Car-ton Rotating ~pparatus). Thus, through the
processes occurring at Wor~ Station I~I the carton blan~
100 is provided with a liquid-tigh-t seal along its side
and one end thereof>
Referring again to Figure 30 r the detailed construction
and operation of -the componen-t systems oE Work Station III
is illustra-ted. ~s sho~7n, the crossbar mandrel 400
:~ includes four individual mandrels 402 which are each
preferably welded at one end to a mounting plate 404.
These mounting plates 404 are attached across the fla-ts
of a square arbor 408 by a plurality of fasteners 406.
The free end of each individual mandrel 402 is
p~ovided with a die ~12 secured to the mandrel 402 by a
pair of socket head machine screws al4. ~s shown in
Figure 31, the edges of the die 412 are ~ormed having
a raised land section 416 which includes four recessed
pockets 418 formed on respective cor.ners. As will be
explained below, the raised lands 416 provide a hardened
surface area which aids in the subsequent end bondîng
process, whereas the recesses 418 rel:ieve the stresses
formed in the corner areas of the carton blank 100 and
additionally allow the excess car-ton material which
overlaps at ~he carton corners to be main-tained beneath
the outer surface of the lands 416 during bonding. The
die 412 adaitionally includes a concave channel 420 which
extends across one edge thereof and is aligned with a
similar channel 422 which ex-tends partially throughou-t
the length of each oE the crossbar mandrels ~02 -to recei.ve
the stra~J 220~
~3132~5
69
~ stop ~llO is mounted proximal one edge of the
crossbar mandrel 400 and is connected to a mechanical
linkage 411 which selec-tively reciprocates in a direction
S indicated b~ the arrow in Figure 30. The stop 410 is
biased tightly against one edge of the individual mandrel
402 by a spring 413 and is formed having a shou:Lder 415
intermediate its lèngth~ As will be described below,
this stop registers the carton blank 100 on the individual
mandrels 402 and additionally, when actuated, moves the
carton blan~ 100 radially outward along the leng-th of -the
individual mandrel 402 for contact with the folding
apparatus 440. The lower edge (not shown) of the stop 415
is preferably rounded, so thatr as the ar~or 408 rotates,
the stop ~15 may cam into spring~biased contac~ wi-th
each of the mandrels 402.
Aligned with and located verticall~ above one edge
of the mandrel 402 is a side sealiny apparatus 430 of the
present inven-tion which welds the carton segment 108 to
, 20 the sealing tab 120, thereby permanently maintaining the
square tubular configuration of the carton blan~ 300
As sho~n, the side sealing apparatus 430 includes an
ultrasonic sealing horn 432 having an elongate section
which terminates having an end 434 formed to grab or cam
the extreme edge of the carton blank 100~ As shown in
~igure 28A, in the preferred embodiment, the end 43~
is formed having a substantially planar portion 434A
and a curvilinear portion 434B which protrudes downward
below the por-tion 434A to extend over the corner of the
carton blank 100. At the intersection between the
portions 434A and 434B, a sharp edge 434C is formed which
as will become more apparent below, forms a camming means
which pulls the carton segment 108 toward the corner of
the mandrel 402.
The sealing horn 432 is mounted to the piston 436
of a pneumatic cylinder 438 which selectively extends and
retrac-ts the sealing horn 432 to contac-t the mandrel 402.
'75
The p~ ma-tic cylinder 438 is secured to the housing
~nok shown) and is located inbc,ard and at an angle with
the mandrel 402, such that, when re-tracted (as shown
S in Figure 33) the individual mandrel 402 of the crossbar
mandrel 400 is free to rotate upward through a 90 arc.
In addition, the sealing hoxn 432 is moun-ted by means
(not sho~m) to permit sligh-t freedom of movement in a
direction parallel to the length of the horn 432 but
restricted from movement in a plane perpendicular to the
length of the horn 432. As such, the horn 432 is
self-aligning with the mandrel 402 to effectuate a proper
bond or seal during operation~
Disposed adjacent one end of the mandrel 402 c~nd
mounted proximal thereto, is the folding apparatus 440
which permanently bends the sealing tabs 120 formed
along the ends of the carton blank 100 against the lands
416 o~ the die 412~ The apparatus 440 preferably
includes a T-shaped jaw 442 disposed beneath the lower
20 surface of the mandrel 402 and a pair of side jaws 4~4
~ which are mounted adjacent bo-th sides of the mandrel 402.
: Each of these jaws is connected to an appropriate linkage
(not shown), typically being cam actuated, such that the
T-shaped jaw 442 reciprocates in a vertical directionr
whereas the side jaws 444 reciprocate in a horizontal
direction as indicated by the respective arrows of Figure 30.
Sprin~ loaded and disposed vertlcally above the
individual mandrel 402 and in a common plane therewith is
a roller assembly 446 illustrated schematically in Figure
30 30. Basically, the roller 446 includes a relieved cylinder
448 having a reduced diameter section 449. The width of
the section 449 is preferably sized to equal the wid-th of
the end closure panel 112 with the angular transition 451
between the reduced diameter section 449 and the main
diameter of -the roller 448 sized to tightly abu-t the sides
of the carton blank 100. As shown, -the roller 446 is
xotatably mounted to a shaft 450 connectecl as by way of
i ~
71
springs (not shown) to the housi.ng (not shown).
The roller 446 is accurately positioned radlally
ou-tward from -the mandrel 402 such tha-t, as the i.ndividual
mandrel 402 rotates upward through a 90 arc, the reduced
diameter section 449 of the cylinder 448 contacts and ro~ls
across the end closure panel 112 of the carton blank 100 at a
poin-t tangent to the raised lands ~16 of the die 412.
As may be easily recognized, by contac~ing the end closure
panel 112 during the rotation of the mandrel 402, -the
roller apparatus 446 folds the end closure panel 112 over
the end of the die 402.
With -~he struckure dæfined, the operation of -the
component sys-tem.s of Work Station ~II may be described.
As shown in Fiyure 30~ the carton blank lO0 is transferred
tQ th~ ;n~ a~ rel.402 at the nine o'clock position
ol ci~ c-l~s'~-ar m~ dLel 400 in a mannex previousl~
described with one edge of -the blank 100 contac-ting the
shoulder 415 of the stop A10. The stop 410 is initially
~r 20 spaced from the ena of the die 412 an appropriate distance
selected so that, upon abutment with the shoulder 415, the
en-tire length of each of the car-ton segments 102 through
1.08 lies slightly radially inward of the land sections 416D
While in this position, the pneumatic cylinder
Z5 operator 438 is energized, causing the sealing horn 432
to extend in a downward direction and contact the carton
blank 100 adjacent one edge of the mandrel 402. While in
this extended position, the end 434 of the sealin~
horn 432 extends partially on both sides of the edge and
firmly presses the carton secti.on 108 ayainst the sealing
tab 120. Due to the end 434 having the particular
configuration shown in Figure 28A, upon contacting the
carton blank 100, the carton section 108 is grabbed and
pulled tightly toward the co.rner of mandrel 402 by the
sharp edge 234C and curved protrusion 434B t.hereby forming
a tight corner. The horn 432 is then energized by well
known driving apparatus r and the sealing tab 120 is bonded
2~5
to the carton segment 10~ by an ul-trasonic ~7eld.ing process
which is well known in the art, however, alternative methods
of forr,linc3 the bond, such as heat sealing, may be utilized.
~hus, by this ultrasonic weldiny process, a liquid-tight
seal is formed along the edge of the carton blank 100
which permanently maintains the square tubular
configuration of the carton blank 100.
Subsequent to this ultrasonic ~Jelding process, the
pneumatic cylinder 438 is de-activated to retract the
sealing horn 432 into a stored position as indicated in
Figure 33O Since, as previously described, the pneuma-tic
cylinder operator 433 is mounted inboard and at an angle
with the plane of the crossbar mandrel 400l upon
retraction, the crossbar mandrel 400 is clear to rotate
in a clockwise direction as indicated in Figure 33. Prior
to this rotation of the crossbar mandrel 400, ho~ever,
the sealing tabs 120 located adjacen-t the outer end of
the individual manarel 402 must be ~olded over the end of
the die 412.
In the preferred embodiment, this folding procedure
is accomplished quickly and easily by the folding apparatus
440. With the sealing horn ~32 retracted from the edge of
the car~on blank 100, the caxton blan~ 100 is maintained
on the mandrel ~02 only by frictional forces and~ therefore,
may be easily positioned along the length of the mandrel
402. To expose the sealing tabs 120 beyond the end of the
die 412, for the subsequent folding operation, the stop
410 driven by the linkage 411 moves radially outward from
its initial position ~as shown by the phantom lines in
Figure 33~, thereby pushing the carton blank 100 partially
off the end of the mandrel 402. Upon movement through this
: short distance, the scoring lines 122 formed adjacent the
edges of the carton se~ments 102 through 106 of the carton
blank 100 (as shown in Figure 3) are alignea with the
outside edge of the lands 416 of the die 412. ~s
previously men-tioned, these scoring lines 122 weaken the
73
carton blank material, thereby insuri.ny that the fold
will occur at the desired position along the car-ton blank
100 .
The sequence of operations performed by the folding
apparatus ~40 is illustrated schema-tically in Fîgures 32A-
through 32C. With the sealing tabs 120 extending over the
edge of the lands 416, -the T-shaped jaw 442 of the folding
apparatus 440 reciproca-tes in an upward vertical
direction to a height slightly .above the lower surface
of the mandrel 402 (as shown in Figure 32A) During this
movement, the jaw ~42 contacts the sealin~ tab 120 along
its top edge and crimps the tab 120 tightly against the land
section 416 of the die 412.
Subsequently, the side jaws 444 are activated and
move partially inward from their initial position shown in
Figure 32A to the position shown in Figure 32B, wherei.n
: their leadiny edye ex-tends to the vertical plane of the
side edges of the die 412. During this partial lnward
movement, the eage of each of the side jaws 444 contacts
the lower corners of the sealing tabs 120, causing the
lower corners to be tightly creased between the T-shaped
jaw 442 and the side jaw 444. Due to the T-shaped jaw
~42 remaining in its extended position above the lower edge
of the mandxel 402, the sealing tab 120 is prevented from
springing away from the die 412 thereby insuring an accurate
corner folding of the sealing tab 120.
Subse~uently, the T-shaped jaw 442 reciprocates
slightl~ downward to a position wherein its relieved
corners 442A are aligned with the lower corners of the die
412 and the side jaws 444 reciprocate fully inward across
the frontal plane of the die 412 as shown in Figure 32C~
As previously described in relation to the T-shaped
jaw 442, upon their full inward travel, the side jaws ~44
contact the sealing tabs 120 of -the carton blank 100 and
thereby tightly crimp or fold the sealing tabs 120 over the
lands 416 of -the die 412. Thereaf-ter, the side jaws
2~
7~
44fi are similarly reciprocated back to their original
position as shown in Figure 30. As best shown in Figures
32A, 32B, and 32C, the right side jaw member 444 is formed
sligh-tly shor-ter in length than the lef-t side jaw member
444~ The applicant has Eound this lenyth dif:Eeren-tial
is desirable to eliminate the possibility of the sealing
tab 120 -tearing in the vicinity of the upper corner due
to its integral intersection (sho~n in Figure 3) ~7ith the
10 end panel 112. As such, during the seali~g tab fold-over
process, the portion of the sealing tab in the upper
right-hand corner is not tiyhtly creased against the
face of the die 412 but rather is only urged against the
die 412 for subsequent creasing by the roller apparatus
15 4~6
Thus, upon completion o~ the movement of the T-shaped
jaw 442 and the side jaws 444, the sealing tabs 120 are
folded over the end o~ the die 412 and are oriented within
the square tubular configuration oi the car-ton blank
. 20 100 as shown in Figure 32~ Additionally, it will be
recognized that, due to the V--shaped scoring notches 124
formed on the cart.on blank 100 (shown in Figure 5), the
corners of the sealing tabs 120 will consistently be
folded flush with the carton segments 102-108 (any excess
25 material lying within the square cross-section o~ the
carton blank 100), thereby being properly positloned for
the end closure sealing and bonding operation~
Wi-th the sealing tabs 120 folded over the end of the
die 412r the crossbar mandrel 400 subsequentl~ rotates in
30 a clockwise direction through a 90 arc as indicated by
the arrows in Figure 33 During this rotation, -the
carton blank 100 passes beneath and contacts -the roller
apparatus 446, thereby causing the end closure panel 112
to be folded down over the end of the die 412.
Referxing jointly to Fiyures 33 and 34, the det.ailed
operation oE this rolling procedure is illustrated
While the carton blank 1.00 is carried by the individual
~3 51;Z75
n;andrel 402 in the nine o'clock position, the end panel
112 extends beyond the end OL the die 412 with the scoring
line 11~ ~shown in Figure 3) being aligned with the top
edge of the land section 416. As the individual mandrel 400
rotates from the nine o'clock to twelve o'clock positiont
the ou-ter edges of the lands 416 pass closely beneath the
cylinder 4~8 of the roller apparatus 446, whereby the
end closure panel 112 contacts the reduced diameter
section 449 of the cylinder 4~8. ~his contact forces the
end closure panel 112 in a downward direction (from its
initial position indicated by the phantom lines in Figure
34) tightly against the top surface of the die 412.
~he cylinder ~48 presses the end closure panel 112
tightly against the land sec-tions 416 of the die 412 and
rotates across -the end of the clie in a direction indicated
by the arrow in Figure 34. As the cylinder 448 rolls
across the end of the die 412, the angular transition 451
between the reduced diameter section 44~ and the main
diameter of the roller 448 tightly mates with the sides
of the carton blank 100, thereby preventing the sides
as well as the sealing tabs 120 o~ tne carton blank from
springing outward from the mandrel 402~ Further, during
this rolling process, the excess carton blan]c material
disposed in the corners o:E the square tube (as previously
mentioned and shown in Figure 32) is forced within the
recess pockets 418 of the die 412 (as shown in Figure
31) such that the corners of the sealing tabs 120
are maintained within a common plane with the remainder
of the sealing tab 120, contacting the land section 416
o~ the die 412. Thus, upon passing benea-th the roller
apparatus 446, one end of the carton blank.100 is folded
and positioned upon the die 412 for subsequent bonding~
Upon completion of the 90 rotation of the crossbar
mandrel 400/ the carton blank 100 carried by the mandrel
: 402 is oriented in a ver-tical twelve o'clock posi-tion as
shown in Figure 33 and is registered or ali.gned beneath
L8~
76
the sealing die or horn 450. While in this twelve olclock
position, the sealing horn 450, which had been retracted
in a stored posi.-tion vertically above the end oE the mandrel
5 402 taS shown in Figure 30) is lowered directly upon the
end closure panel 112 (as shown in Figure 33). In the
preferred embodiment, this downward travel of the sealing
horn 450 is provided by a pneumatic ylinder (not shown),
which is mounted by means (not shown) to permit the
horn 450 to move slightly in a plane parallel to the top
surface of the die 412 thereby self-aligning itself with
the mandrel 402. The bottom surface of -the sealing horn
450 preferably includes a shallow pocket (not shown) formed
having a cross-sectional area slightly greater than -that
of the end panel 112 so that the sealing horn 450 may extend
-partial.ly down over the end of the carton blank 100 when
contacting the end closure panel 112.
In this lowered or extended position/ the sealing horn
450 presses firmly against the end closure panel 112,
thereby el.iminating any raising of the end closure panel
112 from the sealing tab 120 caused by the memory proper-ties
(previously described) of the carton blank material and
eliminating a misalignment with the mandrel 402~
Subsequently, ultrasonic energy is applied to the horn 450,
from sui-table driving means (not shown), thereby bondiny
the end panel 112 to the sealing tab 120, and ~orming a
liquid tight seal along the end of the carton blank 100.
After this bonding process, the sealing horn 450 is
retracted vertically to its stored position above
the end of the mandrel 402 by activation of the pneumatic
cylinder (not shown).
Having sealed the end closure panel 112 to the sealing
tabs 120, the crossbar mandrel 400 rotates through an
additional 90 arcl to position the individual mandrel 402
carrying the carton blank 100 in alignment for transfer
to the carton rotator and conveyor transfer apparatus of
Work Station IV.
~l f
77
Although for illustra-tion purposes, a single carton
element 100 was described passing -through the processes
of Work Station IIII it will be recognized that, upon each
90 rotation of -the crossbar mandrel 400, an additional
carton blank 100 is transferred to the individual mandrel
402, such that three carton blanks axe carried by a
respective three mandrels 402 of the crossbar mandrel
400 at most times. Additionally, it will be recognized
that, sirice in the preferred embodimen-t, there
are four crossbar mandrels aoo attached to the arbor 408
(as shown in Figure 5), four individual carton blanks
are being formed simultaneously by the apparatus of the
present invention. Each of these mandrels ~00 moves
intermittently through the 90 arcs described, pausing ln
sta-tionary positions at the quadrant loca-tions for the
described operations.
~ork Station IV - Carton Rotator and Conveyor Transfer
Apparatus
Follo~Jing the sealing operation performed at Work
Station III, the carton blank 100 is transferred to the
horizontal conveyor belt 550 which carries the carton
blank 100 -through the remaining Stations of the apparatus
of the present invention. However, as may be recognized
25 from Figure 33, if the carton blank 100 were transferred
in its present orientation upon the crossbar m~ldrel 400
directly to the conveyor 550, the other end closure panel
114 which extends beyonA the length of the carton segments
102 through 108 would lie perpendicular to the horizontal
travel of the conveyor 550, thereby obstructing the
operations to be performed at Work Stations V, VI, and
VII. Thus, to eliminate the obstruction problems
associa-ted with the end closure panel 114 r pricr to the
transfer of the car-ton blank 100 onto the conveyor 550~
the carton blank :L00 is rotated 90 about its horizontal
axis such that the end closure panel 114 lies in a parallel
planar orientation with the travel of the conveyor 550~
78
Referrinc~ to Figure 35, there is shown the carton
blank rota-tor mechanism designated generally as 480 which
transfers the carton blank 100 from the crossbar mandrel
400 (of Work Station III) -to the horizontal conveyor 550
and rota-tes the carton blank 100 through a 90 axial arc.
_- - .. .. _ _ ., ... ._ ... _ ... ~ .. .. ___~,
27~i
79
Although for illustration purposes only a single carton
blank rotator 480 is shown r it will be recognlzed thatl
in the preferred embodiment, there are four carton blank
ro-tators 480, each positi.oned adjacent the end of the
respective crossbar mandrel 40Q.
As shown in Figure 35, the carton blank ro-tator 480
includes a transfer and ejector mechanism designated
generally by 482 and a rotating fix-ture apparatus 4~4
which cooperate with each other in transferrincJ and
rotating the carton blank 100 from -the crossbar mandrel.
400 to the conveyor loader 550.
The transfer and ejector mechanism 482 preEerably
includes a transfer arm 486 and an ejector arm 488 whlch
are each rota-tably mounted to a slider mount 490 and 492,
respec-tively~ The slider mounts 490 and 492 are spaced
vertically apar-t and are each reciprocally mounted to a guide
pin 494 and spline shaft 496 which extend between a pair of
support columns ~98. These guide pins 494 are rigidly
2Q mounted to the support columns 498, whereas the spline shafts
496 are rotatably mounted thereto, and extend through one
of the support columns 498 at one end. The spline shafts
496 addi-tionally engage the transfer and ejector an~s 486
and 488, respectively, such that rotation of the shafts
496 cause a corresponding pivotal movement of both arms
486 and 488.
As shown in Figure 35, the spline shafts ~96 are
both provided with gear drives 500 and 502 which are
interconnected by a timing belt 504 to rotate both spline
shafts 496 simultaneously. Additionally, the diameter of
the gear 500 is preferably greater than the diameter of
the year 502 such that the ejector arm 488 pivots through
a greater arc for any given rotation of the transfer arm
~86.
~ounted on the rear surface of the support columns
498 is a chain drive 506 which is connected in a
conventional manner at one end to a ~echanical
2~
drive to power ~he chain 506 back and forth repea-tedl~.
Each of the slider mounts 490 and 432 are securely attached
to this chain drive 506 so that, as the motor (not shown)
powers the chain drive 506, the slider mounts travel
horizon-tally between the support columns 498 along the -
~uide pins 494 and spline shafts 496. Since -the slider
mounts 490 and 492 are initially connected to the chain
drive 506 while positioned adjacent opposite support
columns 498, and since the moun-t 490 is connected to the
top of the chain 506 loop while the mount 492 is
connected to the bottom of the loop, it will be recoynized
that, upon movement of the chain drive 50~, the slider
mounts 490 and 492 travel between the columns 498 in
opposed directions, i.e., as the slider moun-t 490 moves
from left to ri~ht as indicated by the arro~J in Figure35,
the slider pla-te 492 moves from right to left. As will
become more apparent below, this opposed movement allows
the carton blank rotator 482 to begin transferring the
carton blank 100 Erom l~lork Sta-tion III, while simultaneously
depositin~ the carton blank 100 into the horizontal
conveyor 550.
As shown, the transfer arm 486 includes an ~-shaped
extension 508 which terminates in a substantially rectangular
head member 510. Both the extension 508 and head 510 are
preferably formed having a hollow interior aperture (not
shown) which is connected to a vacuum source ~not shown).
The frontal face of the head member 510 is additionally
provided with a plurality of vacuum aper-tures 512 which
extend into an interior aperture ~not shown) of the head
510 and extension 508 such that the vacuum source is
exposed at the por-ts 512 to -the front surface of the head
510.
Located in a parallel plane and adjacent to the
transEer e3ector mechanism 482 is the ro-tatin~ fixture
apparatus 484 which is securely mounted to the housin~
514. The fixture apparatus 484 incluaes a hollow
f r
7~
~ 1
rectanguLar fix-ture 516, prefer~bly formed of a sta.inless
steel sheet material, having an open sicle wall configuration.
The fixture 516 is connected at its ends -to a pair of
cylindrical bearing plates 518 which are rot,atably
mounted to the support posts 520. The fix-ture 516
additionally includes a bracke-t 522 moun-ked on its lower
surface ~shown in Figure 37~ which is connec-ted to a
linkage 524. As will be described below, movement of the
1~ linkage 524 causes the fixture 516 to rotate in a counter-
cloc]cwise direction as viewed in Figure 35 such that
its open side is orien-ted with or faces the transfer
and ejector mechanism 482.
The sequence of operations performed by the carton
blan~ ro-tator 480 (Work S-tation IV~ is illustrated in
. Figures 35~38. As shown in Figure 36 r the ro-ta-ting fixture
apparatus 484 (Figure 35) is aligned with and spaced from
the end of ro-tating crossbar mandrel 400 o Work Station
III. While in this position~ the transfer arm 486 is
~r 20 extended into its extreme fon~ard position and vertically
lowered r whereby the face of the rec-tangular head 510
contacts the closed end panel oE the car-ton hlank 100 (as
shown by the phantom line in Figure 35)O Upon contact
kherewi-th, the vacuum source acting through the apertures
512 on the face of the head member 510, pull -the carton
blank 100 tightly against -the face of the head member 510
such -that the car-ton member 100 rnay be carried exclusively
by the arm 486.
It will be recognized tha-t the lowering of -the transfer
arm 486 to the position illustrated in Figure 35 was
initiated by the clockwise rotation of the upper spline
shaft 496O Further, since both spline shafts 496 are
connected by the timing belt 504, this clockwise ro-tation
causes a similar lowering of the ejector arm 488 from its
posi-tion shown in E'igure 35, to the position illustrated
in Figure 36~ Lowered in this position, the ejector arm
488 is inboard oE -the support post 520 of the rotating
,!
;27~
~2
fixture apparatus 484 r and may subsequently travel in a
horizontal direction across the length of the rotating
fixture apparatus 484 without ohstruction.
With the transfer arm 486 and the ejector arm 488
disposed adjacent opposite support posts 498 (shown in
Figure 35) the chain drive mechanism 506 is activated,
causing the sl.ider mounts 490 and 492 to travel
hori~ontal].y along the guide pins 494 and the spline shafts
496 in opposed directions, as indicated by the arrows in
Figure 36.
Since the carton blan~ 100 is maintained against -the
head S10 of the transfer arm 486 by vacuum, during this
horizontal movement, the ca ton blank 100 is removed from
the crossbar mandrel 400 and drawn into the hollowr square
fixture 516.
The square fixture 516 is sized to have a slightly
larger cross-sectional area than that of the carton blank
100 and the head 510, such that insertion within the square
fixture can be accomplished easily with minimurn friction.
Further~ it will be recognized that, auring this placement
of the blank 100 into the square fix-ture 516, the L-shaped
extension 508 of the transfer arm 486 lies within -the open
side of the square fixture 516 and may travel throughout
the lenyth of the square fixture 516.
The opposed horizontal travel of the transfer arm
486 and the ejector arm 488 continues until the slider
mounts 490 and 492, respectively, are adjacent the
support posts 498 (as shown in Figure 37). In this position,
the carton blank 100 lies completely w.ithin the square
fixture 516 and is aligned to be rotated in a counter~
clockwise direction throuyh a 90 arc by the rotating
fixture apparatus 484.
In the preferred embodirnent, this 90 rotation is
facilitated by the actuation of the linkage 524 in a
; . direction indicated by the arrow in Figure 37. By this
~ . movement of the linkage 524, the ~ixture 516 rotates abo~t
~ 3
the cyli.ndrical bearing plates 518 mounted within the
suppor-t posts 520, whereby the open side o the fixture
51~ (as shown in Figure 35) faces the transfer and
5 - ejection mechanism 482 and is aligned for the subsequent
tra.nsfer of the carton bl.ank 100 into the conveyor 550.
Followiny this rotation of the carton blank 100
and square ~ixture 516, the spline sha-f-ts 496 are
rotated in a cou~lterclockwise direc-tion, as indicated by
the arrows in Figure 3a ~ thereby pivotiny -the trans:Eer
arm 486 and the ejector arm 488 vertically upward into
their posi.tions illustrated in Figure 38. Raised in this
position, ~he ejector arm 488 is aligned with the open
side of the square fixture 516, having its tab 518
extending to abut the end of -the carton blank 100 while the
transfer arm 48~ extends vertically above the axial plane
of the fixture 516.
Subsequently, the gear drive 506 ~as shown in Figure
35) is activated in a reverse c~irection from its previous
travel, causing the slider mount 492 and the ejector arm
488 to travel in a direction indicated by the arrow in
Figure 38, ~hile the slider mount ago of the transfer arrn
48~ simultaneously travels in an opposed direction. Thus,
the tab 518 of the ejector arm 488 contac-ts the edge of the
carton blank 100 and pushes the carton blank 100 through
the length of the square fixture 516. As the carton blank
100 is pushed out from the square :Eixture 516, it is
supported by an LYshaped bracket 520 which aligns the
end of the carton blank 100 for entry into the horizontal
conveyor 550.
Thus, from the above, it ~7ill be recognized that, by
use of the carton blank rotator 480 of the present
invention, the carton blank 100 is transferred from Work
Station III to the conveyor transport 550 and is rotated
through a 90~ rotation such that the end closure panel 114
of the carton blank 100 is disposed in a plane parallel
to the travel of the conveyor 550. ~dcli-tionally, it will
be noted that, subsequent -to -the completed horizontal
'~ .
27~ii
travel of ~he ejec-tor arm 488 s~herein the carton blallk 100
is deposited upon the conveyor 550, the transfer arm 486
has moved to an extreme forwara position and may be
5 rotated in a dos~n~7ard direction for a repetition o:E the
cycle previously described. Similarly, upon transfer
of the carton blank 100 into the conveyor 550, the
linkage 524 is activated to return to its initial
position as shos~n in Figure 35, such that the open side .
of the square fixture 51h faces upward in a vertical
dixection.
Semi-Rigid Transport Conveyor
Referring now to Figure 39, the detailed construc-tion
of the conveyor 550 and the entry o:E the carton blan}~ 100
therein may be described. As shown, the conveyor 550 is .
preferably composed of a plurality of elongate bar
members 552 which are arranged in pairs and oriented in
a parallel configuration with each other. Each pair of the
bar members 552 is rigidly attached (preferably by a
r' 20 fillet weld) at both ends to a connector rod 554 which
maintains the parallel orientation of each pair of bar
members 552. Consecutive pairs of the bar members 552
are then formed into a continuous conveyor length by plural
link members 556 which are rotatahly mounted to both
adjacent connector rods 554 and secured thereto by
fasteners 558. Each of these fasteners additionally mounts
a roller bearing 55~ s~hich meshes with a gear drive 561
ana supporks the conveyor 550 upon a pair of horizontal
rails 563. By such construction, the conveyor 550
pxovides a semi-rigid structure s~hich has sufficient
strength to adequately support the carton blanX 100
through the subsequent formation, filling and bonding
processes, yet flexible enough to form a conveyor transport.
Disposed on each pair of bar members 552 and rigidly
attached thereto, are four U-shaped anvils or yoXes 560
preferably formed from hardened tool steel which are
constructed to tightly conform with the outside surfaces
of the carton blank 100. The upper surface of anvil 560
adjacent the interior ~alls thereof is provided with a
beveled edge 562 t~'nich is preferably formed at a 45
angle and includes an enlargecd radius at each o:E its
interior corners. As will be explained i.n more detail
infra, this beveled edge 562 coopera-tes with the pre-form
apparatus of Work Station V to prepare the carton blank
100 for the end closure process, and additionally mates with
an ultrasonic horn (Wor~ Station VII) ~Jhich forms a liquid-
tight seal across the open end oE -the carton blank 100.
To ensure the rigid mounting of the anvil 560 to the
bar members 552, a support plate 564 possessing the same
general shape but making an opening sligh-tly greater than
the anvil 560, is ali~ned ~itn the anvil 560 ancl rigidly
attached to the ~ndersurface of -the bar members 552.
Pre-Eerably, a series of fasteners (not sho~n) are inserted
through all three members, i.e., the support plate 56~,
the bar members 552 and the anvil 560 from the undersurface
of the conveyor 550 such that any relative movement between
- 20 these elements is eliminated.
As will be recognized, the conveyor 550 is held taut
between two pairs of gear drives 561 (one of which is
shown in Figure 39) located at opposite ends of the conveyor
and mounted to a shaft 565 ~hich is connected in a
~5 conventional manner to the main hydraulic drive system
(not shown). In the preferred embodiment, the gear teeth oE
the drive engage the conveyor 550 intermediate adjacent pairs
oE roller bearincJs 558 and driv2 the conveyor 550 in an
intermittent, cy~lic manner (indicated hy the arrows in
30 Figure 39) such that each anvil 560 is momenkarily
stationary at pre-determined intervals along the length of
the conveyor travel. As tlill become more evident belo~,
-khis stationary period allot~/s the appara-tus oE 17Or~ S-tations
V khrough VIII to operate on the carton blank 100~
To support the bar members 552 intermediate their
ends, a plurality of pairs of rigid support tabs or ears
86
557 preferably formed of Delrin (a hard plastic ma-terial
possessing high ~ear characteristics), are located beneath
the conveyor 550 positioned at eaeh of the Work Stations
V through VIII. As shown in FicJure 39~, tlle support
plates 564 rigidLy connec-ted to the undersurface of the
anvils 560, rest against the ears 557, thereby preventing
any downward deflection of the bar members 552 and anvil
560 during operation. In addition to the support ears 557
positioned at the Work Stations, the eonveyor 550 incluaes
a pair of rigid bars 567 which extend throughou-t the
length of the conveyor 550. As sho~m in FLgure 3gA, the
rigid bars 567 are spacecl from one another at a aistanee
slightly greater than the wid-th across each oE the car-ton
segments 102-108 and varied in their vertical distance
from the anvils 560 such -that they may maintain the
carton blank 100 in a vertical orientation while being
earried by the conveyor 550.
Located intermediate each pair of rigid bars 567 and
20 disposed substantially below the plane of the conveyor 550
is a lower support bar 569 which is connected to a hydraulic
actuator (not shown~. As illustrated in Figure 39A, the
lower support member 569 contacts the lower end of the
earton blank 100 thereby maintaining the vertical heigh~
25 of the earton blank 100 upon the conveyor 550. Additionally,
as indicated by the phantom lines in Figure 39A, the lower
support member 569 is movable in a vertical direction by
aetuation oE the hydraulic opera-tor (not shown), thereby
accommodating the differing sized containers (1/2 pint and
30 1/3 quart) of the present invention.
Side-Loader Mechanism
~ . ...
Disposed beneath the conveyor 550 and located
tangentially adjacent one end thereof, is a side loader
mechanism 570 which is ver-tically aligned with the plural
35 carton blanks 100 as they are transEerred from the carton
blan~. rotators 480 (oE Work Station IV and sho~n in Figure
38), In the preferred embodiment, this side loader
,, !'
7S
87
mechanism 570 simultaneously loads the ~our sepaxate
carton blanks 100 received from the carton blank rotators
480 direc-tly upon the conveyor 550.
As better shown in Figures 40 and 40A, the side loader
mechanism 570 preferably includes a plurality o~ C shaped
fixture plates 572 which are spaced from one another along
a mounting beam 575 at a distance slightly greater than the
distance across parallel flats of the carton blank 100~
10 This relative spacing permits a single carton blank 100
to be received between adjacen-c fixtures 572 along the
: mounting beam 575.
As shown, the vertically e~tending sidewalls 577 of
each fixture pla-te 572 are formed havi.ng a tapered top
15 edge ~ich in the preterred embodiment is formed with an
acute angle of less than 45. The fixtures 572 are each
rigidly at-tached to the mounting beam 575 which is in turn
connected to a linkc~ge 573~ Upon activation of the linkage
573, the beam 575 ancl thus the fixtures 572 move in a
20 horizontal transverse direction toward the open end of the
anvil 560. This horizontal movement of the fixtures 572
enters and accurately positions the plural carton blanks
100 within the anvil 560~ As will be explained in more
detail infra, the tapered top edge of the sidewalls 577
25 of each of the fixtures 572 permits the return transverse
movement oE the fixtures 572 within the interior of the
conveyor 550 without contacting the car~on blanks previously
loaded and carried by the conveyor 550.
The detailed operation of the transfer of the carton
30 blank 100 from the carton rotator and conveyor transfer
apparatus 480 (of Work Station IV) to the conveyor 550 is
illustrated in ~igure 40. In the position shown in
Figure 40, it will be recognized that the conveyor 550 is
momentarily s-tationary in a tangential position aligned
35 with the carton blank rotato.r and the transfer apparatus
480, ~7hereby the frontal planes of ~he anvil. 560 and the
C-shaped fixture 572 are perpendicular to the travel of -the
ejector arm ~88.
~' f
88
While in this posi~ion, the space between adjacent
C-shaped fixtures 572 is registered and aligned with the
carton blank 100 such that the blank 100 mav be directly
transferred from -the carton blank rotator and conveyor
transfer mechanism 480. AS the ejector arm 488 extends
toward the conveyor 550 in a manner previously described,
the carton blank 100, contacting the tab 518 of the ejec~or
arm 488, is transferred to and received between the
C-shaped fix-tures 572~ Since the space between the
C-shapea fixtures 572, as well as the distance between
the bar members 552, is slightly greater than the outside
dimensions of the carton blank 100, the carton blank 100
is easily received between adjacent fixtures 572 without
an~ bending or deformation of the carton blanlc 100 itself.
Once received between the fixtures 572 r the ejector
arm 488 retracts and rotates in a downward direction (as
previously descr;bed) and the carton blank 100 i5 carried
by the mounting beam 575. Subsequently, the linkage 573
attached to the beam 575 is activatedr causing the fixtures
572 and the carton blank 100 carried ~h~orebetween to
move traverse1y toward the open end of the anvil 560.
As shown in Figure 40, during this traverse movement
toward the anvil 560, the car-ton blank 100, extending
substantially beyond the leading edge of -the fixture 572,
enters into the open end of the anvil 560 with the interior
surfaces of the anvil 560 contacting the flats of the carton
blank 100. It will be recognized that, slnce the fixtures
572 are p~sitioned beneath the conveyor 550, during the
traverse movement, the leading edge of the fixture 572 will
travel behind the lower surface of the anvil 560 thereby
allowing the carton blank 100 to enter unobstructed into
the anvil 560.
The C-shaped fixtures 572 continue their t.ransverse
travel until -the leading edge 574 of the carton blank 100
contacts or abu-ts the in-terior wall of the anvil 560. As
previously men-tioned, since -the interior dimension of the
275
89
anvi]. 560 is sized to ti~h-tly recelve the tubular
configuration of the carton blank lO0, the carton blank
lO0 is thereby slightly press-fit into the anvil 560.
Subsequently the conveyor 550 begins its intermittent
travel, whereby the carton blank lO0, maintained within
the anvil 560, moves arcuately upward with the conveyor 55
to an approximate 45 orientation as shown by the nu~eral
lOOA in Figure 39. B.y this travel of the conveyor 560, the
ca.r-ton blank lO0 is removed from between adjacent
C~-shaped fixtures 572 and is carried exclusively by
the anvil 560. Fur-ther, since the sidewalls 577 oE the
: fixture 572 are formed having a tapered top edye,
subse~uen-t to the travel of the conveyor, the mounting
beam 575 and C-shaped fix-tures 572 may _eturn to their
initial position for repetition of an additional loadlng
cycle, wh~rein another set of four carton blanks lO0 may
be t~ansferred from the carton blank rota-tor and conveyor
transfer apparatus 4~0 (of 1~1Ork Station IV)
.~ 20 It will be recognized that the particular transverse
movement of the car-ton lO0 into the anvil 560 in a
direction parallel to the plane of the anvil 560 allows
the open end of the side panels of the blank lO0 to
moderately yield, allowin~ a close fit within the anvil 560.
25 If the carton ~7ere inserted closed-end first, the previously
welded corners would resist any yieldingr and cartons
would be crushed entering the anvils 560
Further, by transferrin~ the carton blank lO0
to the conveyor in the manner previously describedr
30 the carton blank lO0 is continuously supported by the
two sides of the C-shaped fixture 572 as well as the
mounting beam 575 during the carton blank's lO0 entry into
the anvil 560. The applicant has found that this support
of the carton blank lO0 durlng the entry into ~he
35 anvil 560 is preferable to insure against any
deformati.on of the square tubular configuration of the
:~L8~2~S
-so-
carton blank 100 caused by a slight interference fit between
the carton blank 100 and the interior walls of the anvil 560.
E'urther, the applicant has found that this side entry process,
positively positions th~ carton blank 100 in its desired
location within the anvil 560, thereby insuring the accuracy
of the subsequent processes performed on the carton blank 100
while carried by the conveyor 550.
Referring again to Figure 39, it may be seen that, while
carried by the conveyor 550, the top edge of the carton blank
100 is positioned slightly above the top surface of the anvil
560, and the end closure panel 114 is disposed in a parallel
plane to the travel of the carton blank 100 on the conveyor
550. This positioning and orientation of the carton blank
100 upon the conveyor 550 facilitates the subsequent pre-
forming, filling and sealing operations performed at Work
Stations V through VIII, respectively.
Work Station V - End Section 'Pre-Form 'Apparatus
.
With the carton blank 100 positioned upon the conveyor
transport 550 and carried within the opening of the anvil
560, the continued cyclic or intermittent hori~ontal movement
of the conveyor 550 transports the carton blank 100 to Work
Station V (End Section Pre-Form Station). At this station,
the end closure panel 114 as well as the top edges of the
open end of the carton blank 100 are creased or folded by a
discrete three-phase operation into a desired configuration,
suitable for the subsequent end closure bonding and sealing
process, which occurs at Work Station VII. As will become
more apparent below, the apparatus of Work Station V
accomplishes the variety of folding and creasing operations
without the benefit of interior mandrels to work against, i.e.,
all operations occur without the use of supporting means or
forming mandrels positioned on the interior of the carton blank.
-91-
E~owever, the apparatus for producing such a configuration
is substantially modified in the present invention, and
therefor is disclosed herewith.
Referring to Figure 41, the overall construction and
operation of Work Station V may be seen. Work Station V
includes a pre-form apparatus designated generally by the
Numeral 600, which is mounted to a frame member 602 and
located vertically above the conveyox 550. The pre-form
apparatus 600 preferably includes a housing 604 which
supports a mounting plate 606, xigidly attached thereto.
Three die bases 608, 610, and 612 are securely mounted to
the undersurface of the mounting plate 606 and are
horizo~tally spaced at intervals equal to the distance
between anvils 560 ~ounted upon the con~eyor 550.
The dies 608, 610 include a plurality of plate
operators (shown in Figures 43 and 45, respectively) whi.ch,
during operation of the pre-form apparatus 600,
contact the carton blank 100 and cooperate with the die
bases 608~ 610 to permanently crease the carton blank 100
into its desired configuration. These operator plates are
activated by pneumatic mechanisms 614 and 616
(represented schematically in Figure 413 which are mounted
to the top surface of the mounting plate 606 and disposed
within the housing 604, each having an apporpriate linkage
(not shown) extending through the mounting plate 606. As
will be explained in more detail below, each of the die
bases 608, 610, and 612 per~orm an operational phase of the
pre-foxm apparatus 600 and, upon engagement with the carton
blank 100, folds or creases the carton blank 100 in a
particular manner, whereby, upon completion of the travel
of the carton blank 100 through each of these phase
~ 2-
; operations, the carton blank 100 is permanently folded
~ into the particular configuration ind.icated in Figure 51A.
Further, it will be recognized that, although for
illustration purposes only one series of the die bases
~ 5 608, 610, and 612 are shown and described, in the preferred
~ embodiment there are four of each of the die bases 608,
61C, and 612, similarly mounted to the plate 606 and
positioned so as to register with the respective four
anvils 560 carried by each pair of conveyor bars 552.
. 10 ~s shown in ~igure 41, the housing 604 of the pre-form
apparatus 600 is slidingly mounted adjacent its corners
by four posts 620, which cooperate with four bushings 622
rigidly mounted to the housing 604. Each of these posts
620 extends at one end substantially into the housing 604 and
is rigidly attached at the other end to the frame 602. A pair
of push rods Ç03 (shown in Figure 1) located outboard of the
conveyor 550 are rig.idly connected to the housing 604 and are
: engaged with the main transport drive (not shown~ of the con-
veyor 550, to reciproc~te in a vertical direction. As may
be recognized, by such an arrangement, the housing 604, as well
as the die bases 608, 610, and 612 carried thereon, is raised
and lowered in a vertical direction indicated by the arrows
. in Figure 41. In operation, these push rods 603 synchronize
~ the travel of the pre-form apparatus 600 with the travel
j. 25 of the conveyor 550, thereby insuring the proper formation
steps are conducted on each carton blank 100.
` Although for illustration purposes, in Figure 41, the
- housing 604 is illustrated disposed substantially above the
` ~ level of the anvil 560, it should be recognized that, during
- 30 actual operation, the housing 604 only reciprocates upward
through a short distance (approximately 1 to 1-1/2 inches)
such that, while in its lo~ered position, the bottom surface
of the die bases 608, 610, and 612 lie slightly beneath the
top su~face of the anvil 560, and in its elevated position,
''
93
the bot-tom surface o:E the die bases 60~, 610, and 612 lie
slic~htly above the top surface of the anvil 560~ but below
the top ed~e oE the end closure panel 112 of the carton
blank 100. The applicant has found -that this short
vertical travel of the pre-l'orm apparatus housing 60~
significantly reduces the time required for actuation of
the pre-form apparatus 600 and additionally substantially
eliminates any registry problems associated with extended
~ravel of the apparatus.
The sequential operation of the die bases 608, 610,
and 612 of the pre-form apparatus 600 may now be described.
To help illustra-te tlle progression of opera-tions being
performed by the pre-form apparatus 600, -the carton blank
is designated in Figure 41 by the numerals lOOA, lOOB, and
,- lOOC, representing the three separate operational phases
occurriny at the respective die bases 60~, 610, and 6l.2~
With the pre-form apparatus 600 reciprocated to its
initial raised position, as shown in Figure 41, the conveyor
'r 20 550 carrying the carton blanks 100 -thereon, intermitently
travels horizontally in the direction indicated by the arrow
in Figure 41 and positions the carton blank lOOA beneath the
- die base 608. Since, as previously mentioned, the horizontal
travel of the conveyor 5S0 is cyclic or intermi-ttent in
25 nature, upon positioning of the carton blank lOOA beneath
the die base 60~, the conveyor 550 momentarily stops its
travel, thereby facilitating the operation of the pre-form
apparatus 604 upon the carton blank lOOA.
While in this position, the housing 604 is lowered
: 30 onto the carton blank lOOA and the anvil 560 by the push
rods 603, wherehy the first phase operation of the pre-form
apparatus 600 is performea upon the carton blank lOOA~ By
this first operation, the carton blan}~ lOOA is accurately
positioned within the anvil 560, positively seated upon the
35 lower support member 569 and permanently creased along
the free edcJes of the end closure panel lL~ to form three
beveled surfaces 632 (as shown in FicJure ~2).
275
9~
Re:Eerriny to Figures ~3 and 44, the detailed
cons-truction oE the die base 608, and the first phase
operation of the pre-form apparatus is illustrated. As
shown in Figure 43, the die base 608 is formed having a
generally square cross-sec-tion sized slightly greater than
the carton blank lOOA, thereby ex-tending across three edges
thereo-f~ The bottom surface of the die base 608 includes
a recess 621 formecl adjacent three edges -thereof. This
recess forms a boss 623 which is received within the
interior of the carton blank lOOA during operation while
a shoulder 625 formed by the recess 621 contacts the upper
edge of the carton blank lOOA. The back surface (as
viewed from Figure 41) of the die bases 608, includes a
shallow central cavity 634 (Figure 43) havi.ng tapered
angular walls formed at approximately 45 angles r Disposed
outwardly from the back wall of the die base 608 is an
operator plate 630 which is pivotally connected by linkages
631 and 633 to the die base 608 and ~neumatic operator un.it
20 6i4 (shown in Figure ~1), respectively, being movable both
toward and away from the back wall of -the die base 608
as illus-trated by the arrow in Figure 43. The operator
plate 630 is additiunally formed having a projection 636 7
the configuration of which is a mirror image of the concave
cavity 634 formed on the back surface of -the die base 608
During the lowering of the pre~form apparatus 600
toward the conveyor 560, the operator plate 630 is
initially spaced outwardly from the die base 608 (as
shown in Figure 43) such that the end closure panel 114
30 may be received between the interface of the operator
plate 630 and clie base 608. As such, the continued
lowering of the apparatus 600 allows the boss 623 to
en-ter into the interior of the carton blank lCO while the
shoulder 625 formed on the bottom surf~ce of the aie base
608 contacts the top edges of the carton blan~ lOOA and
firmly presses or seats the carton blan~ lOOA against the
lower suppor-t member 56 (silo~/n in Figure 41). As may be
reco~nized, -this seatiny positively re~isters the carton
blank lOOA within the anvil 560, thereby insuring the
accuracy of the subsequen-t creasing and ~olding operations
being performed by the appara-tus 600.
Wi-th the die base 608 lowered a~ainst the top edges
of the carton blank lOOA, the pneumatic operato~ 61~ is
activated causing the operator plate 630 via the lin~ages
633 and 631 ko move toward the die base 60~. In the
preferred em~odiment, this movement of the operator plate
630 is very rapid, thereby imparting a high velocity to
the operator pla-te 630 such that the end closure panel 114
is creased between the cavity 634 and the extension 636.
lS This creasing action causes the end closure panel 11~ to be
forced into and permanently assume the shallow, recessedJ
angular cornered shape of the cavity 634. Suhsequen-tly,
the hydraulic operator 63~ is deactiva-ted, causing the
operator pla-te 630 to move back to its initial position
`r 20 spaced from the die base 608. The housing 604 and thus the
die base 608 is then raised back to its elevated position.
Thus, from the above, it will be understood that, by
the operations occurring at the first phase of the pre-form
apparatus 600, the carton blank lOOA is properly seated in
the anvil 560 and creased in-to a con~iguration illustrated
in Figure 42, having three beveled surfaces 632 forming a
picture-frame-like shape along the edges o~ the end closure
panel 114.
Subsequent to completion of -the first operational phase
30 of the pre-form apparatus 600 (i.e., -the carton blank lOOA
being correctly seated within the anvil 560 and having its
end closure panel 114 creased by the die base 608), the
conveyor 550 continues its intermit-tent horizontal motion,
causing the carton blank lOOB to be posi-tioned and
35 registered beneath the second phase die base 610~
Basically, by this second phase of pre~form apparatus
600, the two corners of the car-ton blank lOOB located
275
96
furthest from the end closure panel 114, are stress-relieved
by bein~ dimpled and pushed ~7ithin the interior of the
carton blank (shown in Figure 46A). Additionally, the
sealing tabs 120 formed adjacent the top three edges of
the carton blank lOOB are bent or folded within the
interior of the carton blank lOOB to be disposed in a
plane normal to the end closure panel 114 ~shown in
Figure 48~
The operations occurrin~ on the carton blank lOOB
and the respective a~paratus of-this second phase of the
pre-form apparatus 600, are illustrated in Figures 45-48~
As shown in Figure 45, the die base 610 preferably includes
three plate operators 650 which are pivotall~ mounted at one
end to the die base 610 by pins 6~1 and are connected at
the other end to the respecti~re ~ne~atic operator 616
by linkages 653 and cross-head 655~ As will be explained
in more detail. below, these operator plates 650 pivot in an
inward direction towards the in-terior of -the carton blank
100 ~Jhen actuated, thereby folding over the sealing tabs
120 of the carton blank lOOB, which extend slightly above
the surface of the anvil 560 ~better shown in Figure 47).
Disposed adjacent the two for~ard corners of the die
: base 610 ~as viewed in Figure 413 are two creasing pins
652 having their respective pneumatic R~M operators 654 securely
mounted to the bottom surface of the support plate 606.
As best shown in Figures 46 and 46~, these creasing pins
are aligned diayonally with the fon~ard corners of the carton
blank lOOB and angularly oriented in a downward direction such
30 that the pins 652, upon actuation, extend slightly within the
interior of the carton blank lOOB~
The detailed operations occurring at the second phase
of the pre-form apparatus 600 may no~J he described. With
the carton lOOB ali~ned under the die hase 610, the housing
604 carryin~ the die base 610 thereon is lowered (as
previously described in relation to the first phase of
the pre-form) onto the car-ton blank loos. As shown in
- -
~88275
FicJures ~7, when the die base 610 is ex-tended to its Eully
lowered position, the ~hree operator pla-tes 650 pivotally
connec-ted to the die base 610 reside partially outboard ~f
the edges of the carton blank lOOB and are angularly
oriented such tha-t their top edges extend within the
interior oE the plane of the carton blank lOOB while
-their lower edges lie partially within the beveled edge
562 of the anvil 560. Further~ disposed in this lowered
position the operator plates 650 lightly touch the top
edge of the sealing tabs 120 extending upon the three
sides of the open carton blank lOOB, thereby causing the
sealing tabs 1~0 to flip slightly inward toward the
interior of the carton blank lOOB, as shown in Figure 47.
This particular slight flexing has been found to
substantially increase the rigidity of the forward
corners of the sealing tabs 120 and aid in the subsequent
corner creasing operation performed in the second phase
of the car-ton pre-form.
Subsequently the pneumatic R~ operators 65~ ~f the cxeasing
pins 562 are ac-tuated, causing the creasing pins 562 to
extend and travel in a direction indica-ted by the
arrow in Figure ~6, thereby contacting the two forward
corners of the carton blank lOOB. As previously
mentioned, since the sealing tabs 120 are rigidified b~
the operator plates 650 a-t their top edge, upon contact
therewi-th, the corners of the carton blank lOOB readily
collapse or deform and are pushed within the interior of
the carton blank lOOB as well as in a slicJht dow.nward
direction. Due to the carton blank lOOB being formed with
the V-shaped scoring notches 12~ (as shown in Figure 5)
located at these respective fo~ard corners, the corners
consistently collapse into a V-shaped orienta~ion as shown
; in Figure ~6A~ As will be recognized, this V-shaped
orientation relieves any stresses in the corners of -the
car-ton blan]c lOOB during the folding operations and
7S
98
effectively miters the forward corners of the carton
blan~ lOOB for the subsequent sealing tab 120 fold-over
operation.
Having the corners of the carton blank lOOs relieved
in such a manner, the creasing pins 652 are retracted back
to their storea position ~sho~n in Figure 46A) and theoperator plates 650 are activated by their respective
pneumatic mechanism 616 to contact and fold over the
sealing tabs 120. This particular fold-over operation is
illustrated schematically in Figure 47, wherein -the operator
plates 650 are shown in their initial position placed
over the carton blank lOOB with the sealing tabs 120
adjacent their lower surfaces. From their ini-tial position,
the operator plates 650 are pivoted downward within the
.~ interior of the carton blank lOOB in a direction indicated
by the arrows to assume a position illustrated by the phantom
lines in Figure 47. As will be recognized, during this
downward pivoting of the operator plates 650, the sealing
tabs 120 are folded over to reside exclusively within the
interior of the carton blank lOOB. As in the previous
sealing tab fold-over operations, the consistency and
accurate location of the fold is insured by the scoring
lines 122 (shown in Figure 3) formed on the carton blank
2S lOOB, which substantially weaken the reslstance to the fold
at a precise location on the carton blank lOOB.
As sho~Jn in.Figure 47, the operator plates 650
pivot through an arc substantially greater than 90 such
that, during the folding operation, the top edge of the
sealing tab 120 initially extends downward wi-thin the
interior of the carton hlank lOOB~ This extended fold-over
o~ the sealing tab 120 compensates for thc slight memory
property of the carton blank material ~as previously
described) so that, when the operator plates 650 return
to their initial position, the sealing tabs 120 will spring
slightly upward, but remain in a plane normal to the exterior
walls of the carton blank lOOB.
3;Z75i
99
As will be recognized, in the ideal situation, the
lower pivot point 651 of the plate members 650 should be
loca-ted a-t the bend point (i.e., the scoring lines 122)
oE -the carton blank lOOB thereby insuring a pure and
consistent bending force being appliea to ~he sealing -tab-
120. However, since all three sealing tabs 120 must be
concurrently folded over, the operator plates 650 must
be spaced from the scoring lines 122 and from one another
to provide suf~icien-t s~inging room during the pivoting
procedure. The outboarcl pivot point 651 of the present
invention provides a suitable compromise structure wherein
the opera-tor plates 650 are spaced from one anothex to
freely pivot simultaneously without contacting each other
and which the applicant has Eound to yielcl consistent
results. As such, during the pivoting of the plate
members 650, the sealing tabs 120 not only pivot downward,
but additionally slides or cams again~-t the lower surface
of the plate members 650. This slicding motion tends to
force the 10~7er portion of the sealing tab 120 to -flex
outward into the beveled recess 562 of the anvil 560.
Hos~7ever, due to the scoring lines 122 weakening the
sealing tab and forming, in effect, a preferential
fold line, this outward fle~ure is held to a minimum
and does not detrac-t from the overall effectiveness of
the fold down operation.
Subsequently, the pneumatic mechanism 616 is de-activated,
returning the operator plates 650 to their oriyinal position
as shown in Figure ~6, and the housing 60~ of the pre-formed
apparatus 600 is vertically raised, therehy removing the
die base 610 as well as the creasing pins 652 carried thereon
from the carton blank :lOOB. Thus, as may be easily
recogrlized, by the operation of the seconcl phase of the
pre-form apparatus 600, the carton blank lOOB is formed into
the configuration shown in Figure ~8 with the sealing tab
120 folded within the in-~erior of the carton blank lOOB,
and lyiny in a plane normal thereto with the two forward
conlers rorming a miter-like corner interface.
275
100
Upon completion of -thc second phase oE the pre-form
appara-tus 600 operation, the conveyor 550 again begins
its inter~ittent horizon-tal travel, thereby positioning
5 -the caxton blank lOOC ~eneath the die base 612 for the
third operational phase of the pre-foxm apparatus (shown in
Figure 41). At this third phase, the top edges oE the
carton blank lOOC are beveled out~ard to ex-tend sligh-tly
be~vond the sidewall sections of the carton blank lOOC
10 and the forward corners are stretched outward or e~panded,
to provide a suitable surface for end sealing, as sho~
in Figure 51~ and described in detail below. In the
preferred embodiment, this procedure is accomplished
effectively and easily by the die base 612 (shown in ~igure
15 49~ being lowered firmly upon the top edge of the carton
blank lOOC.
Referring to Figure 49, i-t may be seen that the aie
base 612 is formed into a generally square configuration
and includes a chamfer 660 along its lower edges. In the
r 20 preferred embodimen-tr this chamfer is formed at approximately
a 45D angle to the bot-tom surface of the die base 612 such
tha-t it mates with the beveled surfaces 562 formed on the
anvil 560 (shown in Figure 50). As shownr the beveled
surfaces 562 of the anvil 560 is provided with a series
25 of circumferentially ex~nding serrations 563 which (as
will be explained in de-tail infra) form a gripping surface
for the anvil 560 during the subsequent end sealing
procedure of Work Station VII.
: The two Eorward corners (as viewed from Figùre 41)
30 Of the die base 612 slightly protrude from the flats of the
die base 612 and are formed into a conical coni~uration
662 ~he outside diameter of this conical protrusion 662
is a mirxor image of the enlarged radii formed at the
respective corners of the anvil 560 (shown in Figure 50).
35 Thus, the lo~er edges of the die base 612 are formecl to
tightl~ mate with the he~eled surface 562 of the anvil 560
such that the die base 612 and anvil 560 cooperate to form
a mold-like ixture.
275
101
As previously described in ~elation to the first two
phases oE the pre-form apparatus 600, in operation the die
base 612 is lowered to~ard the conveyor 550 to contact the
-top edges of the carton blank lOOC. Extended to its fully
lowered position, the die base 612 contacts the sealing
tabs 120 (previously foldecl over -to lie ~.7ithin a plane
normal to the flats of -the carton blank lOOC) and forces
the sealing tabs 120 in a do~mward direction against the
adjacent lower portion of the carton blank lOOC (sho~n in
Figure 51).
The continued clo~nward pressure of the die base 612
; ~orces the carton blank lOOC and its sealing tab 120 to
reside between the beveled surfaces 562 of the anvil 560
and the chamrered edges 660 of the die base 612. As such,
the top edges of the carton blan~ lOOC are beveled outward
Ir
and e~-tend sli.~htly beyond the vertical planes of the carton
seyments 102-108 oE the carton blank lOOC (as shown in
Figure 51) and the serrations 563 are pressed slightly
-, 20 into the lo~7er surface of the top edges of the carton
blank lOOCo
It will aclditionally he recognized that, during this
procedure, the forward corners of the carton blank lOOC
are stretched to conform to the conical corners 662 of the
25 die base 612 and the enlarged radii formed in the anvil
560. Thus, the for~7ard corners of the carton blan~ lOOC
are formed having an outer enlarged radius as clearly sho~n
in Figure 51A
: Subsequently, the die base 612 is raised in a vertical
30 direction by -the push rods 6~2 tFigure 1) in a manner
. previously described, ~7hereby the sealing tabs 120 spring
upward tdue to the moderate memory properties of the carton
blank material) slightly.
Thus, from the above, it may be recognized that, upon
35 completion of its travel through the pxe-form apparatus 600
and its three--stage operation, the upper or open edges of the
carton blank lOOC are pre-formed into a configuration
-
~8~ S
102
suitable to the subsequent end sealing and bonding operationp
without the use of forming mandrels or the like being
inserted ~7ithin the interior of the carton hlank 100
during operation. Further, by the pre-forming process,
the upper edges of the carton blank 100 are formed in
an up~ard-facing picture-Erame-like structure which mates
with the configura-tion of ~he end closure panel 114.
Additionally, it will be recognized that each of the three
phases previously described in -reference to the
pre-form apparatus 600, occurs simultaneously for each
lo~ering of the pre-form apparatus 600 aown upon the carton
blan~s lOOA, lOOB, and lOOC.
Work Station VI - Filllng Sta-tion
Following the pre-form apparatus operation, the car-ton
blanks 100 are transported by the conveyor 550 to l~ork Station
VI ~the Filler Station). At this station, the car~n blanks
100 are filled with a desired liquid by a two-stage
operation ~lerein, at the first stage, a pre-fill nozzle
supplies a slight majority ~approximately 60%) of the
liquid to the carton blank and, at the second stage, a
topper nozzle accurately fills the carton to the precise
liquid level. In the preferred embodiment, both of the
nozzles, i.e., the pre-fill and topper nozzles, are
2S constructed in the same manner, with the differences in the
quantity of liquid delivered into the carton being
controlled by the ad~ustable displacement of a metering
pump positioned on each of the nozzles.
As will be reco~lized, to fully utilize the space
reduction made possible by the rectanyular configuration
of the container 12 (shown in Figure lA), the carton blank
100 must be filled with the desired liquid to a level
proximal the open end of the carton blank 100. As such, the
container 12 of the present invention is highly s~sceptible
to spillage durinc; the filling operation. Further, since~
in the preferred embodiment, the end closure bonding and
~8~32~5
103
sealing operation (occurring at l~ork Station VII) is
accomplished wi-th an ultrasonic ~elding process, it is
desirable that, duri.ng the filling operation, liquid does
not splash ~r ~oam Gn~o the seali-~g tabs 120 formed at
the open en~ of tlie ca~ton blank 100.
To facilitate bo-th of these ohjectives, a novel
filling nozzle and metering pum.p app~ratus is utilized
which, in the preferred e~bodiment, are combined into a
single integral unit providing a positive liquid
displacement, a high volume, low velocity discharge, and
an accurate discharge shu-t-o-Ef which significan-tly reduces
the possibility of accidental over-fill and splashing o
the liquid during filling. Further, an alternative nozzle
device is disclosed ~hich includes all of -the above
performance features and is specifically adapted for
1~
use with a cons-tant volume and cons-tant pressure pump
wherein li~uid metering is accomplished exclusively by
an internally reciprocating spool.
Additionally, a novel pump and valve operating and timing
mechanism is disclosed ~hich synchronizes the operation of
the me-tering puTnp and nozzle with respect to the motion
of the carton blanks upon the conveyor and provides an
automatic and manual no-fill mode which prevents fluid
discharge when a carton blan~ 100 is no-t positioned under
the nozzle or when desired by the operator.
Referring to Figure 52, the detailed construction of
the nozzle 700 and metering pump 740 of the present
invention is shown. The nozzle 700 is formed having a
yenerally cylindrical configuration and is preferably
fabricated ~rom stainless steel such that the corrosive
effects of the liquid passing therethrough are minimal.
A large central aperature 702 extends substantially through
the length of the nozzle 700 and communicates with an
enlarged torroidal cavi-ty 704 formed concentric therewith.
Adjacent the closed end o-E the aper-ture 702 is an aperture
port 706 which extends radially in~ard from -the exterior
3Z~5
-104-
of the nozzle 700 into the upper end of the aperture 702.
The aperture 702 is enlarged at its lower end to form a
discharge cavity 708 having a beveled or conical inside
diameter 710. As will be explained in more detail below,
this beveled diameter 710 provides a valve seat for a
nozzle spool 712 and additionally directs the liquid passing
through the end of the nozzle 700 inward towards its own
center line.
Disposed within and slidingly received by the aperture
702 is a noæzle spool 712, preferably formed in a closed end
tubular configuration~ the length of which is less than
the length of the aperture 702. The spool 712 includes
a plurality of elongated channels 714 which extend along the
Qute~ diameter thereof and are located such that, when
the-lower end of the spool 712 is seated against the
beveled diameter 710, the top edge o each of the channels
~ 714 reside slightly below the lower surface of the
eniarged torroidal cavity 704.
The lowex end of the spool 712 is proyided with a
20 ~ e cap 716 including a beveled edge 718 which mates with
. the beveled diameter 710 formed on t~e end of the nozzle 700.
In the preferred embodiment~ this valve cap 7~6 if formed
of ~ELRI~, a relatively hard plastic material, possessing
a slight resiliency which, when pressed against the
b~veled diameter 710, provides a positive shut-off for
the noz.zle 700.
The upper end of the spool 712 is preferably formed
having a closed end 720, the outside diameter of which is
slidingly ~eceived within the aperture 702 and is provided
wit~ ~n. ~-ring seal 721 which forms a liquid-tight seal
between the spool 712 and the aperture 702. As shown,
the O-ring 721 is disposed within an annular recess 723
~ormed in the spool 712 and travels with the spool 712
during xeciprocation within the aperture 702.
The upper closed end 720 is provided with an upward
projection 722 having a generally conical shape which
*Txademark
7~ii
105
serves as a bumper for the internally moving spool 712
as it slides in ~n upward direction within the aperture
702. As shown, the upper end 720 prefe~ably includes an
arm linkage 711 which is rotatably mounted in a ball and
socket arrangement 713 at one end~ and extends horizontall~
through an aperture 70~ formed in the upper portion of
the nozæle 700. The linkage 711 is pivotally mounted
intermediate its length about a pin 715 which is rigidly
connected to the frame (not shown~ of the apparatus
10. The opposite end of the linkage 711 is adjustably
connected to a push rod 717 which communicates with a
linkage drive (not shown). As will be recognized, by
vertically moving the push rod 717 in the direction of
the arrows in Figure 52, the spool 712 reciprocates
within the cen-tral aperture 702.
The inlet to the nozzle 700 is formed by a vertical
: . aperture 724 ~^7hich extends from the upper surface 726 of
the nozzle into the enlarged torroidal cavity 704. The
20 upper end of -the inlet aperture 724 is tapered in diameter,
Eorming a beveled shoulder 728 which, in the preferred
embodiment, cooperates with a ball check valve 730. The
check valve 730 is supported on its lower surEace by a
spider cylinder 731 having a plurality of radially exkenaing
webs 733 which slidingly engage the cylindrical walls of
the aperture 724. Both the spider cylinder 731 and check
valve 730 are biased against the shoulder 728 in a
conventional manner by the spring 732. This ball check
valve 730 permits flow into the inlet aperture 724 but
;30 prevents any reverse flo~ therefrom
:During operation, the spool 712 ver-tically reciprocates
within the aperture 702 and functions both as a sh~t-off
valve for positively sealing the discharge end of the
nozzle, and a flow control valve for met~ring the passage
of liquid through the nozzle
The particular flow con-trol properties o~ the spool
712 are made possible by the design of the channels 714.
i, ~ . .. .
2~S
106
These channels 71~ are designed such that the ratio of
the flow cross-section o~ the channels 71~ to the outle-t
flow cross-sec-tion 70~ is essentially a constant value
throughout the opening and closing o-f -the nozzle 700,
with the outlet.flow cross~section being considerably
greater than the channel flow cross-section. As such,
as the liquid travels through the channels 714, it is
free to flow into the larger discharge cross-sectional
area 708, thereby dissipating fluid pressure and
attenuating fluid velocity. Thus, the liquid exits the
nozzle 700 at a substantially reduced velocity which
yields laminar flo~, thereby allowing the carton blan~.
100 ~o be ~illed without the possibiliky of ~plash-over.
Additionally, slnce the nozzle 700 of the present
invention utilizes an internally moving spool 712, ra~ner
than an externally moving spool as utilized extensively
; in the prior art, upon discharge from the nozzle, the
liquid is directed by the beveled diameler 710 inward,
. 20 to~Jards the center line of the nozæle. This inward
directed flow allows the diameter of the nozzle discharge
to be formed as large as the open end of the carton blank
100 into which the liquid is being deliVered, thereby
facilitating a high volume liquid flow rate. Further,
the internally reciprocating spool 712 of the present
invention specifically eliminates the entrapment of air
under the nozzle dlscharge whicn occurs in the prior ar~
nozzles~ -thereby greatly reducing foam generated during
the filling process~ In Figure 52C, a conventional pr.ior art
nozzle "N" is shown, having a spool "S" outwardly
reciprocable (in a direction indicated by the arrow in
Figure 52C) to valve the discharge !'D". Typically9 ~he
spool "S" is normally closed by a spring biasing
arrangement (not shown) which permits the outward movement
of the spool "S" (i.e., opening of the nozzle) in response
to incoming fluid pressure. Such an arrangement always
results in a minimum discharge opening for a glven liquid
27~i
107
flow ra-te which yields a maximum discharge velocity. ~s
shown, during opera~ion, the conventional nozzle "N"
discharges liquid over the end of the spool "S"
creating an umbrella-like flow configuration. This
umbrella configuration entraps air beneath the spool "S"
and above the rising liquid level which generates
substantial foam formation in the liquid "L". The
genera-tion of foam adversely effects filling accuracy
and additionally promotes splash-over during the filling
operation. Additionally, although some prior art nozzles
have attempted to alle~-iate the air entrap~ent problem
by ven-tiny the air through a central aperture (not sho~)
formed axially through the spool "S", such attempts have
proven incapable of pro~iding a complete solutlon. In
contradistinction to the conventional prior art nozzle,
the internally reciprocating spool 712 of the present
invention comple..ely eliminates the air entrapment
problem associated duriny -the filling operation. As
, 20 shown in Figure 52D, during filling, the spool 712
reci.procates upward, allowing the liquid to flow througn
the discharge 708 in a conveying flow configuration.
~5 such, the umbrella of the prior art is eliminated with
its attendant air entrapment and foam generation being
~5 eliminated. Thus, due to the high volume, low velocity
flow rate through the nozzle, filling of the car-ton blank 100
occurs rapidly~ wi-thout the possibility of li~uid splashing
onto the top edge of the carton blank 100.
By reference to ~igure 52f the detailed operation of the
30 nozzle 700 of the present invention may be easily
recognized~ In the preferred embodiment, the spool 712
is reciprocated vertically within the aperture 702 of the
nozzle 700 by the downward reciprocation of the
push rod 717 which is transmitted to the spool 712
35 via the linkage arm 711. During this movement~ -the spool
is drawn upwara toward the closed end of the aperture
~38~75
108
702 until the protrusion 722 of the closed end 720
contacts the upper wall of the aper-ture 702. With the
spool 712 raised to this elevated position, the channels
714 co~municate with the e~larged cavity 704 and the lower
DELRIN cap 718 is removed from the seat 710, such that the
nozzle 700 is opened, and -the liquid flows through the inlet
aperture 724, channels 714, and discharge cavity 70~ oE the
nozzle 700.
Alternatively, the nozzle ?oo may be closed or shut
off by reciprocating the push rod 717 in an upward
vertical direction, whereby the spool 712 is forced in
a downward direction wi-thin the aperture 702, isolating
the channels 714 from the enlarged aperture 704 and
: 15 simultaneously seating the DELRI~ cap 71~ tightly against~
the beveled diame-ter 710 of the noz.zle 700. This tight `~
sealin~ of the cap 718 positively shuts off flow through.:
the nozzle 70Q and eliminates any dripping of liquid fxom
:~ the end thereof.
t 20 Although, in the preferred embodiment, this
reciprocation of the spool 712 within the aperture 702
i.s accomplished by the reciprocation of the push rod
717, it should be recognized that, alternatively~ the
uppex end of the aperture 702 may include a vacuum port
25 (not shown) which extends radially outward in the vicinity
of the port 706 and ls connected to an alternating vacuum-
pressure supply. In this regard, a three-way solenoid
operated valve (not shown) may be mounted to the
vacuum port ~not shown), and connected to both a constant
30 pressure line and a constant vacuum line (not shown3 which,
by the operation of the solenoid, may be alternatively
~ exposed to the vacuum port to facilitate the rapid
: reciprocation of the spool 712 ~7ithin the aperture 702
The amount of liquid passing through -the nozzle 700
35 is controlled by the metering pump 740 of the present
invention which is preferably rigidly mounted to the top
.
9L~81~Z75
109
surface of the noz~le 700. As shown in Fiyure 52, the
metering pump 740 includes a bell-shaped cylinder housin~
742 having an aper-ture 744 e~tending throughout i-ts length
Adjacent the lo~er end of the housing 742, this aperture
7~4 is enlarged to form a pumping chamber 746 which
communicates directly with the inlet aperture 724 of the
nozzle 700.
To prevent any leakage between the metering
pump 740 and the nozzle 700, an O-ring 748 is provided
along the periphery of the interface between the metering
pump 740 and nozæle 700 and is clamped and maintainea in
position by a collet 750 which extends arotmd the exterior
diameter of both the metering pump 7~0 and noæz1.e 700.
Disposed within the chamber 746 is a purnp piston 752
having an elongate upper section 754 and a lower head
member 756~ The diameters of the elongate sec-tion 754
and the head memher 756 are sized slightly less than the
.~ diameters of the aperture 744 and pump chamber 746,
respectively, such that the piston 752 may slide vertically
within the housing 742. Additionally, both the elongate
section 754 clnd the head me~ber 756 are provided with
O-ring seals 758 and 760, respectively, which prevent
leakage of liquid between the piston diameters and the
housing apertures.
An elongate aperture 762, preferably formed concentric
with the piston 752 and extending throughout its length~
provides a liquid inlet for the metering p~p 740~ As sho~m
in Figure-52~the inlet aperture 762 includes a valve 764
biased in a closed position by a spring 766 and re~istered
within the aperture 762 adjacent both ends by a plurali~y
of guide projections 768. As will be recogniæed, the valve
- 764 allows liquid passage into the pumping chamher 746 but
prohibits any flow of liquid in a reverse direction through
the inlet aper-ture 762.
In operation, the pump piston 752 is initially raised
upward through the lenyth of the pumping chamber 746 by a
2~7~
110
rigid linkage 780 (shown schematically in Figures 53~55)
attached to the upper end of the elongate section 754
During this up~ard travel, the pressure of the incominy
l.iquid within the inl.et aperture 762 (produced by the
static head of liquid cont.ained in storage reservoir
763, shown in Figure 1) causes the valve 764
to move off its seat or open/ thereby allowing liquid to
fill the volume of the chamber 746. The pressure within
the aperture 762 and within the chal~ber 746 rapidly equalizes
at the end of this stroke, so that, due to the biasing :Eorce
of the spring 766, the check valve 764 closes or sea-ts
against the bottom surEace of the piston 752.
Subsequently, the piston 754 is forced in a do~mward
direction b~ the rigid linkage 780 (shown in Figures 53-55),
thereby displacing the liquid contained in the pumpinq
chamber 746 through the ball check valve 730 of the nozzle
700. During this do~1nward travel or pumping stroke of the
metering pump 740, the spool 712 of the nozzle 700 must be
vertically raised within the structure 702 (in -the manner
previously described) such that the channel 714 communicates
with the inlet aperture 724. As such, upon reciprocation
of the piston 754, the entire volume o-E l.iquid contained
within the pumping chamber 746 flows through the nozzle
25 700 and is deposited within the carton blank 100.
Subsequently, upon completion of the pumping stroke~ the
spool 712 of the nozzle 700 moves verticallv downward,
seating against the beveled diameter 712, thereby providing
a positive shut-off for the noæzle 700~
It will be recognized that, in basic principle, the
metering pump 7~0 of the present invention is conventional
in design in that it simply provides a posi-tiv~ displ~cement
piston pump includin~ an inlet and outlet check valve.
However, since in the present invention the metering pump
35 740 is combined ~ith the nozzle 700 to form a single in-tegral
unit, the mechanism provides siynifican-t improvements over
the prior art designs.
g~5
111
sesides the obvious size and weigh-t reduc-tion benefits
made possible b~ such a design, the present invention
significantly reduces -the volume of the liquid passages
on the outlet siae of the metering pump 740, thereby greatly
reducing the possibility of air ingestion into the liquid-
in the event that the spool 712 is not precisely timed to
open and close at the beginning of the pump piston 752
travel. Further, since the lower surface of the piston 752
bottoms out directly against the top surface oE the nozzle
700 at the end of the pumping strol~e, the en-tire volume
contained within the pumping chamber 746 is displaced
through the nozzle 700, such that an~ air entering the
system is swept out during each successive pumping cycle
and will not accumulate in the pumping chamber. As will
" be reco~ized, this lac~ of air accumulation significantly
~ increases the accuracy of the liquid quantity being
; delivered on each pumping cycle. Additionally, since the
inlet to the pumping chamber 7~6 is concen-tric with the
, 20 piston 752, any leakage through the valve 764 during the
pumping cycle is substantially eliminated by the positive
seating of the valve 764 caused by the increased PressUre
developed by the downward movement of the piston 752.
An al-ternative embodiment of a filler nozzle suitable
for use in the present invention as well as many other
filling applications is shown in Figure 52A. The
alternative nozzle 950 includes a generally cylindrical-
shaped body configuration formed of an upper and lower
housing portion 952 and 954, respectively. As with -the
nozzle 700 of Figure 52, the nozzle 950 includes a central
aper-ture 956 which extends in an axial orientation
substantially throughou-t -the length of both the upper
and lower housing portions 952 and 954. Adjacent
cpposite ends of the lower housing portion 954, the
central aperture 956 is enlarged to form two flow
cavities 958 and 960. As shown, the upper flow cavity
958 co~municates with the nozzle inlet 962, whereas the
lower flow cavity 960 forms the outlet 964 of the nozzle 950.
275
112
Disposecl wi-thin the cen-tral aperture 956 is-a spool
966, the outside diameter of which is sl.ightly less than
the diameter of the aperture 956 such that the spool 966
may reciprocate. The spool 966 may be provided with a~
end cap 968 rigidly attached aajacent one end thereof which .
is preferably fabricated of DELRIN and formed to -tightly
ma-te with the beveled circumference o:E the nozzle outlet
96~ As will be recognized, when this cap 968 is seated
upon the outlet 964, the nozzle is valved with all flow
through the outlet 964 being prohibited.
Intermediate the length of the spool 966, a plurality
of flow channels 970 are formed which are spaced
symme-trically about the circum-ference of the spool 966~
As with the emboaiment of Figure 52, these flow channels
970 selectively communicate bet~een -the uPper and lower
flow cavities 958 and 960 thereby forming a meteriny
passageway for liquid flowing through the noz~le 950.
At the intersection between the upper and lower
housing portions 352 and 954, respectively, a cap seal
assembly 972 is provided which provides a Liquid-tight
seal between the housing portions 952 and 954 as well as
a low friction seal around the circumference o~ khe spool
966. As best sho~m in Figure 52B, the cap seal assembly
972 resides in an annular recess 974 formed in the lower
housing portion 954 and includes an O-ring 976 and C-shaped
seal 978. The C-shaped seal 978 is constantly biased
against the periphery of the spool 966 by the O-ring 976
and is compressed between the u~per and lower housing
portions 952 and 954 to prevent leakage between the
housing portions 952 and 954
In the preferred embodiment, the seal 978 is fabricated
from a moderately stiff yet resilient elastomeric material
which effectively forms a liq~lid-~iyht seal with the spool
966 yet possessing a small coefficient of friction to allow
-~he spool 96~ to readily reci.procate within -the aperture
956. As will be explained in more detail belowJ this low
friction stationary ~ap seal configuration elimi.nates any
~8!32~5
113
liquid displacement duri.ng the closing of the nozzle
caused by the piston effect oE a sealiny member (such as
the O-ring 721 of -the nozzle 700 of Figure 52) reciprocating
with the spool 970 within the aperture 956.
The upper housing portion 952 is pre-ferabl~ provided
with a control chamber 980 which com~unicates with the
upper end of the central aperture 956 and accommoda-tes
the bumper portion 982 o:E the spool 966. As shown, the
control chamber 980 communicates with a vacuum pressure
port g86 which may be connected to a vacuum and pressure
source (not shown)~ As will be recognized, due to the cap
seal assembly 972 being disposed between the housing portions
952 and 954 and tightly sealing against the spool 966, the
control chamber 980 and upper portion of the central
aperture 956 are isolated from liquid passing through
the nozzle. As such, the control chamber 980 may be
utilized to raise and lower the internal reciprocati.ng
- spool g66 within the central aperture 956. In response to
~ 20 the alternative application of vacuum or pressure to the
port 986~ Further, in the preferred emhodiment, an
additional port 984 is provided which may be provided with
an air switch (not shown) or other similar device for
sensiny when -the nozzle 700 is in its open and closed
position.
In operationt the nozzle 950 is pre-erably connectea
to a constant pressure liquid supply (such as the elevated
liquid reservoir 763 of Figure 1) which is connected to
the inlet 962 of the nozzle 950 by means of the conduit
988. To permit liquid to flow through the nozzle 950,
vacuum is selectivel~ applied -to the vacuum port 986 which
causes the spool 966 to reciprocate upward within the
aperture 955, thereby unseating the end cap 968 from the
outlet 964. Liquid enterina the inlet 962 then flows
through the flow channels 970 in-to the enlarged cavity
960 and through the outlet 96~.
In the preferred embodiment, the effective area of
the :Elow channels. 970 is formed to be less than the area
7S
11~
oE the lowex cavity 960 such tha~ the incoming liquid
pressure may be dissipated and velocity attenuated through
the valve 950 (as previously described in relation to
the nozzle 700 of Figure 52). Additionally, the nozzle
950, due to its in~ernally reciprocating spool 966 and
angularly beveled discharge 964 proviaes an a~ially
converging liquid discharge which, as previously
mentioned, eliminates air entrapment beneath the nozzle
discharge and foam generation during the filling
operation.
To discontinue the flow of liquid through the nozzle
950, the vacuum to the port 986 is terminated and pressure
is applied thereto, thereby causing the spool 966 to
reciprocate downward toward the outlet 964. Due to the
cap seal 972 remaining stationary during this reciprocation
process, it will be recognized tha-t the effective area of
the spool 966 remains constant during closing. This same
effective area prevents any displacement during the
closing operation which would be present with the O-ring
seal moving with the spool 966, and thereby eliminates
the piston effect which causes a portion of the liquid
contained within the aperture 956 to rapidly squirt from
the discharge 964 during closing.
~urther, in the preierred embodiment, the flow
channels 970 are formed to provide a substantially
constant ratio bet~een the cross-sectional flow area of
the channels 970 to the outlet 964 throughout opening
and closing of the nozzle 950. As such, the rluid velocity
remains at a constant value during closing of the valve
thereby yielding laminar flow.
Thus, the flow channels 970 perform a metering effect
which~ in combination with the cap seal asseI~ly 972,
provides an effective shut-off nozzle which eliminates
~8~7~i
115
any pi.s-ton effec-t during closing and effectively opexates
with only one movincJ part, i.e., the spool 966.
Referring now to Figure 53, the opera-ting and timing
mechanism 780 of the present inven-tion for synchronizing
and adjusting -the operation oE the filler nozzles with
respec-t to -the motion of the carton blan~s 100 carried
by the ~onveyor 550 will be described. It should be
noted that, for illustration purposes, the operating and
10 timing mechanism 780 are described in relation to the
nozzle 700 and metering p~np 740 assembly of Figure 52.
However, the same operating and timing mechanism 780
; may be modified for use with the alternative nozzle 750
of Figure 52A without departing Erom the spirit of the.
15 present invention.
As shown in Figure 53, the operating and timing
mechanism 780 comprises a mechanical linkage driven by a
cam operator 788 which is powered by a constantly rotating
shaft 790 synchronized with the drive system ~not shown)
.~ 20 Of the conveyor transport 550. The cam 788 converts the
rotation of the shaft 790 in-to a reciprocating motion
which drives a cross-head 792 via a vertical push rod 794
As will be recognized, the cross-head 792 is rigidly
attached to this vertical push rod 794 such tha-t the
~5 vertical push rod 794 and the cross-head reciprocate
as an integral unit in a vertical direction in response
to the rotation of the cam 788.
Opposite ends of the cross-head 792 are con~ected to
adjacent metering pumps 740 by way of a drive l.inkage 796
30 having one end thereof pivotally mounted to the cross~head
792 and the other end thereof pivotally connected to a
rocker arm 798~ As shown, the rocker arms 798 are rotat.ably
: mounted intermediate their len~th to the piston 754 of the
metering pump 740 to form a central pivot, and are additionally
35 provided with an adjus-tahle pivot 800 at their opposite
ends. This adjustable pivot 800 connects one end of the
~8~7~
116
rocker ~rm to ~1 air or hyclraulic cylinder 802 which is
pivo-tally mounted -to the machine frame 804.
Since the metering pump 740 and nozzle 700 are
additionally riyidly mounted to the machine frame 804,
it will be recognized that, upon the vertieal reciproeated
travel of the cross-heads 792, caused ~y the rotation of
eam 788, the pis-tons 754 of the metering pumps 740 are
raised and lowered ~i.e., comprising the pump stroke of
the me-tering pump 740) by means of the vertical l;n}~aqe
796 and rocker arms 798.
ReFerrinc3 now -to Figures 53 through 55~ the aetailed
operation of the ~.echanism 780 may be described~ In Figure
53, the mechanism 780 i5 sho-.~m in its normal operating
position, having previously completed a pump stroke and
filling operation, wherein the piston 754 is extended to
its lo~Jer-most position against the top surface of the
nozzle 700 (as shown in Figure 52). In this normal
position r the pneumatic or hydraulic cylinders 802 are
, 20 retracted to their upper-mos-t position, therehy providing a
rigid structure for -the pivot point 800 of the rocker arm
: 798.
Referring now to Figure 5a, the operation of the
mechanism. 780 duriny the normal intake stroke of the
metering pumps 740 is illustrated. In normal operation,
the pneumatic eylinders 802 are pressurized to eonstantly
remain retracted to their upper-most posi-tion as shown in
Figure 53 whereby the rotation of the cam 788 causes the
eross-head 792 to raise in a vertical direction~ Upon this
vertical travel of the cross-head 792, the rocker arms 798
pivot about the points 800, which are rigidly maintained
in a stationary position by pressure exerted upon -the
cylinders 802, thereby raisincJ the pump pistons 754. As
previously described, during this upward pump piston 754
travel, the incoming liquid opens the chec]~ valve 764 and
fills the pumpiny cham~er 746 (shown in FicJure 52~ of the
pumps 7~0.
Continued rotation of the cam 788 eauses the cross-head
792 to reciprocate downward, thereby forcing the pump
~L8~27S
117
pistons 754 of the metering pump 740 in a downward
direction, discharging the liquid contained therein
through both nozzles 700.
It will be recognized that, since the vertical travel
of the pistons 75~ is dependent upon the ratio of the
distances between each of the rocker arm end pivots ~00
to the central pivots r minor adjustments on the pump
stroke, and -thus the pump displacement, can be indep~ndently
facilitated by the limited travel o~ the adjustable
pivot 800 along the respective rocker arm 798. As such,
the displacement of each of the metering pumps 740 may
be finely adjusted during operation simply by manually
turning a respective thumb screw 805 positioned on the end
~5 of the rocker arms 798. Further, it will be recognized
that to accommodate substantial differences in the metering
~: pump 740 displacement, the cam 788 may be replaced with a
larger cam having a greater degree of eccentricity.
~eferring now to Figure 55, the operation of the
mechanism 780 in a no-fill mode is illustrated. To provide
a no-~ill mode for one or both of the metering pumps 7~0,
upon completion of the pumping stroke of the metering pump
740 and prior to initiating the intake stroke of the
metering pumps 740, the air pressure maintaining one or both
Of the air cylinders 802 in a retracted position is
discontinued, and nominal air pressure is applied to the
reverse side of the air cylinders 802. By this nominal
xeverse pressure, the air cylinders 802 function in a
manner analogous to a shock absorber being biased and
extending in a downward direction proportionately to the
upward travel of the cross-head 792 and causiny the pivot
point 800 of the respective rocker arm 798 to kravel
vertically downward. By this downward vertical trav~l
of the pivot point 800, the pump piston 75~ does not rise
with the cross-head 7~2, but rather is positively maintained
at the bottom of its stroke against the top surface of the
nozzle 700 (shown in Figure 52). As such, the piston 754
fails to complete its inta~e stroke and fails to receive
. ~
382~
118
liquid for its discharge stroke. Subsequently, upon
completion of the discharge stroke of the cross-head 792,
the hydraulic cylinder 802 may be selectively pressured
in a manner previously described and raised to its normal
opera-ting position for the continued pumping and discharge
cycle.
In Figure 55, this no-fill mode of the mechanism 780
is aepicted wherein the right metering pump 740 is placed
in a no-fill position (i~e., with the air cylinder 802
being ~iased in a downward direction) and the left
metering pump 7~0 is placed in the normal position (iDe.,
with the air cylinder 802 retracted to its upper-most
position). During the r~tation of the cam 788 and the
15 upward travel of -the cross-head 7~2, the left metering
pump 740 raises through its normal intake stroke whereas
the right metering pump 740 is inhibited from moving
upward by the proportional downward extension of the air
cylinder 802. As such, only the left metering pump 740
, 20 recelves a liquid charge during the inta~e stroke.
Further, upon the subsequent pumping stroke, the
downwara travel of -the cross-head 792 overcomes the
nominal reverse pressure exerted in the right air cylinder
802 thereby causing the right air cylindè~ 802 to raise
25 upward propor-tiona-tely to the downward trav~l of the cross-
head 792. ~hus, the right metering pump 740 is main-tained
in its bottomed position against the top surface of the right
nozzle 700~ while the left metering pump 740. discharges
liquid through its respective nozzle 700 in a mann~r previously
described. Thus, by reversing the pressure on a respecti~e
air cylinder 802, at the end of the preceaing pumping stroke~
the operator may selectively prohibit the subsequent
filling opera-tion occurring in individual nozzles 700
without effecting the operation of the remaining nozzle
700 connected to the mechanism 780.
It will be recognized that the cylinders 802 may ~e
advantageously provided with a simple valving arrangement
3f~75
119
to actuate their operation which may be incorparated by a
switch located on the operator's panel (not shown~. Thusr
the selective activation of the cylind2rs 8Q2 may be easily
accomplished by manually tripping the switch. Fur-ther, in
the preEerred embodiment, the mechanism 780 is connected
to a carton blank electronic sensing device (not sho~)
provided on the conveyor 550. Thi~ electronic sensorJ
upon detecting the absence of a carton blank 100 upon
the conveyor 550, automatically reverse pressurizes the
air cylinder 802 such that the no-fill mode of a respective
noæzle 700 is actuated.
In the preferred embodiment, both the pre-fill
nozzles and the topper nozzles (shown in Figure 1) are
provided with their own operating and timing mechanism
780, with the topper nozzle having a cam 788 substantially
smaller than the cam of the pre-fill no~zle such tha-t the
amount of liquid delivered through the toppex nozzle is
much less than the amount of liquid delivered through the
pre-~ill nozzles. Further/ it will be recognized that~
since in the preferred em~odiment, there are four pre-fill
nozzles and four topper nozzles, there will be two operating
and timing mechanisms 780 for bo-th the pre-fill and topper
nozzles. Additionallyl although in the preferred embodiment
a mechanical operating and timing mechanism 780 is shown,
it will be recognized that al-ternatively a hydraulic or
pneumatic actuator connected to each of the pump pistons
50 including an appropriate metering valve system may be
utilized without departing ~rom the teachings of the
present invention.
Work Station VII - End Closure and Bonding Apparatus
Subsequent to the filling operation occurring at
Work ~ation ~I, the carton blank 100, carried by the
conveyor 550, is transported to Work Sta-tion VII, the
End Closure and Bonding Station. At this station, the
end closure panel 114 which heretofor has been extending
yl
z~
. 120
vertically above the surface or the anvil 550, is folded
over the open end of the carton blank 100, a~d then bonaed
and sealed to the sealing tabs 120 (sho~Jn in Figure 3) to
produce the sealed container 12 sho~Jn in Figure 1~.
In the preferred embodiment, this bonding operation
is facilitated by an ultrasonic welding process
(previously describecl in reference to Work Station III),
which signiEicantly eliminates the production of vapors
emitted from the polyethylene film ~rhich could contaminate
the liquid contained within the carton blank 100 an~
addi-tionally settles the adjacent sealing surfaces OL the
carton blank 100 into perfect alignment thereby insurin~
. a positive seal.
Referring now to Figures 56 through 60, the apparatus
; comprising Work Station VII, the end closure and sealing
apparatus, is illustrated As shown in Figure 56, the
apparatus includes a can~ing plate 8S0 which is rigidly
- . mounted to a lin~age 852 and disposed slightly above the top
~ r 20 surface of the anvil 560. Thk plate 850 is preferably
formed of Teflon (a registered trademark of E. I~ DuPont de
Nemours) having a rectangular configuration, one edge 854
: of which is tapered to provide a beveled or camming surface.
Although, for illustration purposes, only one camming
: 25 plate 850 is depicted in Figure 56, it will be recog-nizedthat, in the preferred embodiment, four plates 850 are
utilized being interconnected by -the linkage 852, each
being disposed adjacent a respective anvil 560 of the
conveyor 550.
In operation, the carton blank 100 is transported by
the intermittent cyclic drive of the conveyor 550 to a
position, indicated in Figure 56, wherein the anvil 560
resides adjacent the camming p].ate 850. In this position,
the linkage 852 is activated, causing this linkage 852 to
reciprocate in the direction sho~m by the arrow in Figure
56, whereby the beveled ed~e 85~ of the camming- plate 850
contacts and extends over the end closure panel 114 of the
i carton blank 100 adjacent the top surface of the anvil 560.
~., , , :
3Z75
121
During -this con-tact, the end closure panel 114 is ur~ed in a
downward direction as illustrated by the arrow in Figure 57,
whereby the end closure panel 114 is folded over between
the lower surface of the plate 850 and the anvil 560 to
reside sligh-tly beneath the top surface of the anvil 560
(with the beveled panel 114 a~utting the picture-frame-like
sealing tabs 120.
As will be recognized, since the end closure panel
114 was previously creased by the pre-form apparatu~ of
Work Station V to include a picture~frame-like beveled
edge, during th s fold~over process, the end closure
panel 114 mates with the sealing tabs 120 of the carton
blank 100 maintained against the beveled surfaces S62
formed along the top surface of the anvil 560. However,
. due to the moderate memory properties of the caxton blank
material, the end closure panel 114 tends to spring slightly
upward away frorn the sealing tabs 120 after the operation
of the camming plate 850, as depicted in phantom lines in
- 20 Figure 57. Thus, upon completion of the travel of the
camming plate 850 across the end closure panel 11~, the
end closure panel 114 is substantially folded down upon the
open end o~ the carton blank 100 and is pre-positioned for
the subsequent sealing and bonding process.
~ubse~uently, the conveyor 550 continues its intermittent
travel, thereby positioning the carton blank 100 beneath
a sealing die or horn 860 (shown in Figure 59) which, in the
preferred embodiment, seals the perimeter of the end
closure panel 114 onto the sealing tabs 120 of the carton
30 blank 100. As best shown in Figure 58, the sealing horn
860 is formed having a substantiall~ square cross-sectional
configuration and includes a beveled edge 862 formed ad~acen-t
its bottom surface, as well as a large radius 86A formed
along its two fron-tal corners. The beveled surface 862
and the enlarged corner radii 864 tigh-tly mate with the
complementary surfaces 562 of the anvil 560 such that,
hen the horn 860 is lowered upon the anvil 560, the edges
z~
122
of the end closure p~nel 114 ana the sealing tabs 120 are
pressed tiyhtly between the horn 860 and the anvil 560.
Referring to Figure 59, the horn 860 is supported by a
slider plate 861 disposed above the plane of the conve~or
550. The slider plate 861 is fabricated from two plate
segments 861A and 861B which are maintained toyether by
plural ball bearings (not shown) to permit the plate
segments 861A and 861B ~o sligh-tly move relati~e one
another in a common plane. As shown, the horn 860 is
mounted on the lower plate member 861B and is connected
to an ultrasonic yenerator 866 ~Ihich in turn is rigidly
mounted to the lower plate member 861B. The slider plate
: 861 includes a pair of bushings 863 extending throughout
the height of the slider plate 861 adjacent both ends
thereof, which receive a pair of inclined posts 865~ As
shown, these posts 865 are rigidly mounted adjacent one end
to a pair of support beams 867 extending trans~ersely
across the plane of the conveyor 550, and are angularly
oriented to the vertical plane of the anvil 560. This
angular orientation causes the die 860 to be located inboard
of the end closure panel 114 o the carton blank 100 when
maintainea in its stored position, above the plane of the
conveyor 550, as indicated in Figure 59.
~ he slider plate 861 is additionally pro~ided with a
rigid extension 869 which protrudes adjacent the rear edc~e
thereo~, onto which is mounted a hydraulic or pneumatic
actuator 871 connected to the housing of the apparatus
(not shown3~ As will be recognized, by activating the
hydraulic cylinder 871, the slider plate 861 reciprocates
along the posts 865 in a direction sho~n by the arrows in
Figure 59, thereby lowering and raising the sealiny horn
860 onto the end closure panel 114 of the carton blank 100~
In operation, the sealing horn 860 is lo~ered onto the
end closure panel 114 or the carton blank 100, in an
angular direction as indicated in Figure 60. Due to
the angular orientation of the posts 865 wîth respect to
:
.~
123
the anvil 560, upon contac-tin~ the end closure panel 114,
the die base urges or ca~s the end closure panel 11~
downward and toward the closed end of the anvil 560 such
5 that the end closure panel 114 is properly seated upon the
sealing tabs 120 of the carton blan~ 100 (as indicated in
Figure 58). As will be recognized, the sealing horn 860,
being free to move in a plane normal to the inclined posts
865 due to the bearing interface of the slider plate
1~ segments 861A and 861B, self aligns itself with all ~hreeof the beveled recesses 562 of the anvil 560 thereby causiny
a wedging efFect between end closure panels 114 and the
sealing tabs 120.
While in this position, the heveled ed~es 862 and the
enlarged corner radii 864 of the die 860 firmly press the
r peripheral edges of the end closure panel 114 tightly
against the sealing tabs 120 of the carton blank 100 which
are supported from their undersur:Eace by the beveled ed~es
.~ of the anvil 560. Subsequently, the ultrasonic yenerator
866 is activated, causing the sealing die 860 to rapi.dly
vibrate. This severe vibration results in the settling of
the end closure panel 114 and the sealing tabs 120 in-to
proper alignment with the small discontinuities or
inconsistencies between the interfacing sealing surfaces
being eliminated. Since the anvil 560 is maintained in
stationary position along the conveyor 550 and the lower
surface oE the sealing tabs 120 is gripped by the serrations
563 ormed on the beveled recess 562 of the anvil 560
(sho~7n in Figure 50), this rel.ative vibra-tion o~ the sealing
horn 860 against the anvil 560 generates heat exclusively
along the peripheral edges of the sealing tab 120 and the
end closure panel 11~. This heat causes the polyethylene
coating on the c~rton blank 100 to firmly bond the end
closure panel114 -to the sealing tabs 120, thereby producing
a liquid-tight seal for the carton blank 100, as illustrated
in Figure 58.
As previously men-tioned, this ultrasonic ~elding
process occurs in a matter of fractions of a second,
3Z~5
12~
whereupon, af-ter the sealiny of the end closure panel 114
to -the sealing tabs 120 of the carton blank 100, the
hydraulic cylinder 871 is deac-tivated, causing the slider
plate 861 ~nd the horn 860 to move angularly upward along
-the posts 865 and back to its initial position.
It will be recognized that alternative methods of
sealing the end closure panel 114 to the sealing tab 120
may be utilized in the present invention. However, the
applicant has found that, by use of the ultrasonic welding
process, the liberation of fumes from the polyethylene
substances is significantly eliminated and the polyethylene
is heated exclusively adjacent the periphery o~ the end
closure panel 114 , thereby eliminating any possible damage
: 15 to the coating on the remainder of the carton blank 100.
Similarly, due to the severe vibration of the ultrasonic
welding process, the tab 120 and end panel 114 is
consistently aligned in proper position with voids or
air pockets between the sealing surfaces being comp-)etely
eliminated.
'
~-~
\
.. . . . ..
~L18~275
125
Work Station VIII - Filled Carton Ejector
With the liquid sealed within the carton blank 100,
the final step to be performed on the apparatus 10 of the
present invention is the ejection o~ the carton blank
100 from the conveyor 550. In the pre~erred embodiment,
this ejec-tion is accomplished in a simple yet e~ec-tive
manner at Work Station VIII (the Ejector Apparatus) wherein
the ~illed and sealed carton blan} 100 is expelled from the
apparatus 10 through an aperture 901 for;ned in the housing
14 (as shown in FicJure l)o
Referring to Figures 61, 62, and 63, the ejector
apparatus 900 of the present invention is illustrated.
The apparatus 900 basically comprises a U~shaped rixture
902 which is rigidly mounted at one end to a linkage 90~.
As will be recognized, in the preferred embodiment four
U-shaped ,ixtures 902 are symmetrically spaced along the
linkage 90~ such that all four of the ~illed and sealed
carton blan~.s 100 contained on the conveyor 550 may be
simultaneously ejec-ted ~rom the apparatus.
The common linkage 904 is rigidly attached to ~ cam
plate ',05 having a subs-tantially J-shaped cam run 9~7
formed therein, which cooperates with a cam follower 909
rigidly attached to the housing ~not shown) o~ the apparatus
10. The side walls of the U-shaped fixture 902 are
preferably Eormed having differing lengths 901 and 903 and
are spaced sufficiently apart from one another to slidingly
receive a carton blank 100 therein. As will be recognized,
the apparatus 900 is positioned beneath the upper horizontal
surface of the conveyor 550 and is disposed proximal one
end thereoi to cooperate with the carton blan~s 100 as the
conveyor 550 begins its downward travel over the gear drive
561 tsimilar to the gear 561 snown in Figure 39) and as it
subsequently returns toward l~or~ S-tation IV.
As shown in its stored position in Figure 6:L (this
position corresponding to the phantom line of Figure 63)
when t'ne conveyor 550 begins its downward travel over the
gear drive 561, the U-shaped fixture 902 is aligned with
, ~
12~
the anvil 560 and carton bl~n~ 100 con-tained therein.
As such, the carton blank 1()0 is receivecl between the
differing length side walls 901 and 903 of the U-shaped
fixture 902. ~his downward movement of the conveyor 550
continues until the carton blank 100 is disposed in a
parallel plane with the U-shaped fixture 902 (as indicated
in Figure 61) wherein the conveyor 550 momentarily remains
s-tationary in the manner previously described
While in this stationarY position~ the drive mechanism
~not shown) connected to -the li-nkage 904 is activated,
causing the linkage 904 and -the U-shaped fi~ture 902 to
begin its outward movemen-t toward the carton blank. lOQ in
a direc-tion indicated by the arrow in Fiyure 61. ~s will
lS be recognized, during this initial movement~ the cam follower
909 travels through the short straight section of the cam
run 907, thereby imparting only an outward co~ponent to the
travel of the U-shaped fixture 902 (i.e., toward the anvil
560), which facilitates abutment oE the rear panel 906- Of
the U-shaped fi~ture 902 against the lower end of the
carton blank 100.
Further outward travel of the linkage 904 causes the
U-shaped fiY.ture 902 (following -the cam run 907~ to move
further outward toward the anvil 560 and to simultaneously
move transversely or horizontally across the plane of the
anvil 560 (i.e./ from right to left as viewed in Figure 61),
thereby causing the carton blank 100 to ~lide toward the
open end of the anvil 560. This continued diagonal movement
(i.e., outward and transverse) of the linkage 904 causes
the carton ~lank 100 to be pushed forward through the anvil
560 and outward past the open end of the anvil into the
position shown in Figure 62. As will be recognized, this
diagonal movement avoids interference be-tween the re]atively
rigid carton corners and the anvil 560.
In this position, the car-ton blank 100 is no longer
maintained in the slight interference fit of the anvil
560 and, due to the interior dimensions of the U-shaped
27S
1~7
fix-ture ~0~ being slightly greater than the distance across
the carton segments 102 through 108 of the carton blank 100,
the carton 100 may drop Erom the U-shaped fixture 902 and
be carried away by an auxiliary packaging conveyor (not
shown3.
As will be recognized, by use of the ejector apparatus
900, the sides or carton blank segments 102 through 108 of
the carton blank 100 are supported as they are pushed
outtJard and through the anvil 5600 The applicant has
found that this support of the carton blank 100 during the
ejection process eliminates any possibility of bending or
deforming of the carton blank 100 ~Jhich would occur during
direct out~7ard e~ection of the carton blan]c 100 through the
anvil opening S60. Further, -the ejector apparatus 900 of
,~ the present invention automatically accommodates the
differing sized containers produced by the apparatus 10
: (i.e., lJ2 pint and 1/3 quart~, with the decreased length
of the smaller 1/3 quart container being compensated
r 20 by the initial travel of the U-shaped fixture 902 being
exclusively in an outwara direction which properly enters
the carton within the fixture 902~
~ .
In summary, it will be recognized, that the apparatus
and method of the present invention provides a significant
improvement over the prior art apparatus by providing
the increased versatility of Producing dual-sized
cartons without requiring drastic modification -to the
apparatus. In particular, to change from the one-half
30 pint -to one~third quart size container, the only modifications
necessitated by the presen-t invention are (1) the adjustment
;~ of the L-shaped aliynment block 167 to tightly contact the
smaller length of the car-ton blank segments 102 through 108,
. (2~ the initial pre-loadin~ of the differin~ sized carton
blanks onto the conveyor loader 140 (of Figure 5), (3) the
pre-position of the stop 410 further outt7ard u~on the length
27Si
12~
of -the ~vil 402 to accommodate the shorter leng-th of the
car-ton segmen-ts 102 throu~h 108 (as shown in Figure 22~,
~4) the raising of the lower support members 569 of the
conveyor 550 to the position indica-ted in Figure 39, and
(5) the adjustment of the pivot 800 of the tir~ing and
metering r~chanism 800 to decrease the quan-tity of liquid
discharged through -the nozzle 700 (as shown in Figure 41).
As will he recognized, all of these minor adjustments may
be accomplished in a matter of minutes, thereby easily
facilitating the rrodification of the apparatus and method
of the present invention to produce differing sized
containers 12.
Further, it will he recognized tha-t the present
invention significantly eliminates the space, reliability,
versatility, and output deficiencies associated in the
prior ar-t apparatus which heretofore have prevented the
widespread use and adoption of -the straw bearing cartons
disclosed h~rein.
'r 20 The significant reduction in required floor space was
specifically addressed in each Work Station I - VIII of
the present invention. In particular, the application of
the straw elemen-t to the carton blank, as ~ell as the
sealing oE the -tape length to the carton blank, has been
2~ consolidated to be performed in sequential operation upon
a single rotating drum. Additionally, -the carton blank
has been rotated through a 180 orien-tation upon completion
of its travel through Work Station I, and returned to a
- position proximal its initial orientation upon the aPparatus.
Further, the mechanisms for collating, wrapping, and creasing
the carton blank about the forming mandrels have been
corrbined into a single mechanism with the plural forming
mandrels being spaced from one another at a dis-tance less
than the effective length of the carton blan~s 100.
Additionally, this combined mechanism allows the collating
and creasing of the carton blank to occur simultaneously~
~1l382~5
129
By use of the crossbar mandrel 400 of Work Sta-tion III r
the carton blanks have been sealed upon their side and one
end without the use of a plurality o transport mechanisms.
In addition, once the carton blanks have been inserted upon
the conveyor transport 550, the remaining forming, filling,
and sealing operations occur without relocating or
transferring -the carton blanks to a difEerent support
system.
The reliability benefits made possible by the present
invention are additionally evident throughout each of the
major sub-systems of the apparatus. In Work Stations I and
II, the carton blank 100 has been continuously engaged by a
pair of regis-try tabs adjacent the end panels 11~ and 114,
thereby insuring the proper alignment of the carton blank
100 upon the apparatus. As such, the sealing of the stxaw
element and tape leng-th to the car-ton blank, as well as the
accuracy of the creasing and folding of the carton blank,
has been maintained within positive limits. Further/ the
, 20 use of the conveyor transport 550 throughout Work Stations
III~VIII significantly limits the possibility of misalignment
through the remainder of the apparatus.
The significant increased output of the present
invention over the prior art apparatus has been made
possible by the use o~ both a serial and parallel trac~.c
transport system which advantageously coincides the
particular serial and parallel transport system with those
operations which require -the least and most operational
time, respectively. Further, since the number of transfer
mechanisms have been maintained to a minimum, the overall
cycle time of the carton blanks through the apparatus of
~- the present invention has been si~nificantly reduced.
In addition, it should be noted that J throughout the
disclosure, reference has been made to a main or common
driving mechanism of the apparatus of the present invention
to which all of the major sub-systems are synchronlzed~
~8~275
130
Although the details of this drive system have not been
disclosed, it is well ~ithill the ~nowledg~ of one skilled
in the art to install such a system and synchronize the
operation of each of the various component systems
clisclosed herein with such a main drive.
.
,~ . .
