WO1993002923A1

WO1993002923A1 - Apparatus for and method of applying package fitments

Info

Publication number: WO1993002923A1
Application number: PCT/US1992/006461
Authority: WO
Inventors: Lynn A. Tilley; William B. Peterson; Arthur W. Robichaud
Original assignee: Combibloc, Inc.
Priority date: 1991-08-05
Filing date: 1992-08-05
Publication date: 1993-02-18
Also published as: AU2431992A

Abstract

An apparatus and method are provided for applying fitments onto packages. The present invention includes the steps of: applying an adhesive to a fitment (26); allowing the adhesive to solidify; introducing the fitment to a fitment applicator machine; conveying the fitment to a heating station where the adhesive is reactivated (34); providing mechanical means for picking up a fitment (40); introducing a package to the applicator machine (38); and conveying the package to a position wherein a fitment may be placed on a package and secured thereto (40).

Description

APPARATUS FOR AND METHOD OF APPLYING PACKAGE FITMENTS

The present invention generally relates to an apparatus and method for applying fitments, such as opening and closing devices, onto packages. More particularly, the present invention provides a method and apparatus for high-speed, leakproof application of individual fitments to packages that enable hundreds or even thousands of packages to have fitments attached per hour of operation.

The present invention was developed in the context of paperboard packages, aseptic packages sometimes referred to ^• as "juice boxes" and similar packaging for soups, milk, and other foods and beverages. However, it will be apparent that the present invention will have application to other types of packaging, even packaging for other than food and beverages and for packaging materials other .than paperboard. The apparatus and method of the present invention were developed for applying a small plastic fitment to the previously mentioned packaging for use in opening and reclosing a package. It will be recognized that the present invention would be useful for other than just plastic fitments and other than the particular package fitments described and •shown herein. Typically, in paperboard food and beverage containers, the means for resealing or reclosing a package to store unused contents consists of folding the paperboard in a particular way to close the package. The assignee of the present invention previously obtained U.S. Patent No. 4,915,290 for a package fitment for use on paperboard packages to serve as an opening and reclosable feature that does not leak as often is the case with foldable closures on paperboard packaging. The '290 patent is incorporated by reference herein. A method and machine were needed to apply the fitments to the packages in an automated, high-speed, manner without damaging the integrity of the package or its contents.

The applicator machine of the present invention is a constant motion machine preferably rotating at a set RPM level and capable of applying fitments to several thousand packages per hour. The machine is set up to accommodate a particular size package and is readily changeable to accommodate different sizes. Packages are fed into an infeed section and collected by a star wheel to be transferred into an applicator rotating turret wheel. Fitments are loaded into a feed hopper, sorted in a feed bowl, then oriented and transported to a transfer conveyor. Prior to being placed into the feed hopper, the surface of the fitment that will ultimately be in contact with the package is precoated with an adhesive that at room temperature is firmly bonded to the fitment, but is not capable of bonding to another surface unless reactivated by heat. The fitments, having a preapplied adhesive, now travel through a transfer conveyor on the machine and are indexed over a heating station where the preapplied adhesive is reactivated. The fitments are then collected by pick-up devices mounted on the rotating turret and transferred to the packages, where they are individually placed and held in position on the package until fully adhered. The packages with fitments attached are then removed from the rotating turret wheel by a second star wheel and transferred onto an exit conveyor.

The applicator machine may be equipped with controls for varying the operating speed. An ejector station may be installed on the exit conveyor to collect any packages that are rejected by the applicator control system.

A main drive assembly may be enclosed below the operating deck under the turret wheel. The turret wheel main shaft is driven via a main gear box that may be driven by a variable speed motor. The infeed and outfeed wheels may be gear driven by a main gear mounted on the turret wheel main shaft.

The method of the present invention, begins by preparing the surface of the fitments that will be in contact with the package, by applying a hot melt glue or other adhesive to the surface, manually or by a specially designed apparatus. The adhesive is then allowed to cure on the surface so that it will not tend to stick to anything but the fitment at room temperature in its deactivated state. In this deactivated state, the adhesive is substantially solidified.

In the next step of the process, the previously prepared fitments.are loaded into the applicator sorting bowl. At another location on the applicator machine, the packages are prepared for introduction to the applicator machine. The fitments are transferred from the sorting bowl to a heating station where the adhesive is reactivated. From there, the fitments are transferred to the applicator section and secured to the package by means of the reactivated adhesive. The packages complete with fitments are then ejected from the machine and transferred to secondary packaging equipment

The process may also be arranged for applying the adhesive to the fitment and very soon thereafter securing the fitment to the package without the steps of allowing the adhesive to solidify then reactivating it. Also, the adhesive may first be applied to the package and the fitment placed on the adhesive which is already on the package.. The foregoing and other objects and advantages of the invention will become more apparent when viewed in light of the accompanying drawings and following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a flow chart of one embodiment of the process of the present invention;

FIGURE 2 is a plan view of the applicator machine of the present invention; FIGURE 3 is a side view of the applicator machine of the present invention;

FIGURE 4 is an enlarged detailed plan view of the turret wheel portion of the applicator machine of the present invention;

FIGURE 5 is a section view taken along lines 5-5 of Figure 4;

FIGURE 6 is a prospective view of a fitment pick-up device associated with the main turret wheel of the applicator machine of the present invention;

FIGURE 7 is a prospective view of a package having a fitment secured thereto by use of the method and apparatus of the present invention;

FIGURE 8 is a plan view of a package infeed station on the applicator machine of the present invention;

FIGURE 9 is a side elevational view of the heating station on the applicator machine of the present invention;

FIGURE 10 is a plan view of the fitment conveying mechanism on the applicator machine of the present invention; and

FIGURE 11 is a section view taken along line 11-11 of Figure 10.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S) Referring now to the drawings, and particularly Figure 1, there is described a process, or method, for accomplishing the present invention. The process begins with two separate paths 20,22. The first path ^'20 is concerned with the preparation of the fitments while the second path 22 is concerned with the preparation of the packages. Both paths meet at stage 24 of the process where the fitments are applied to the packages.

The process may begin with step 26 where application of an adhesive to the underside of a base portion of each fitment is accomplished. The adhesive may be a hot melt thermoplastic resin or glue, or equivalent, typically used in assembling plastic components to paperboard structures. One preferred adhesive is Findley No. 335-335 which may be purchased from Findley Adhesives, Incorporated, Wauwatosa, Wisconsin. The adhesive is preferably of a type that, once it is allowed to cure, it becomes generally solid to the touch and adheres to the fitment without tending to stick to other surfaces in its solidified state.

The fitments having the solidified adhesive thereon, may then be loaded 28 into a prefeeder hopper associated with the fitment applicator machine. The fitments may be loaded into the hopper in mass quantities. The fitments move 30 by gravity, or vibration, or otherwise from the hopper into a vibratory bowl. The vibratory bowl may be purchased from Feeder Corporation of America, Melrose Park, Illinois, or equivalent. Loose fitments are collected in the bottom of the vibratory bowl. The vibrating motion transfers the fitments to the top of the bowl along a continuous track around the interior circumference of the bowl until the fitments reach the top of the bowl. Once at the top of the bowl the fitments shift to an outer circumference track around the vibratory bowl. The fitments are then properly positioned 32 through a combination of guide rails and air jets so that they become properly aligned to enter a fitment introduction station on the applicator machine.

The fitment introduction station is a conveyor track designed especially for the size and shape of the fitment. The fitments are conveyed in an orderly arrangement to a heating station wherein the adhesive applied to the fitments is reactivated 34. Various different heating means may be used. In a preferred embodiment an infrared radiation preheater block along with a hot air convection heater reactivates the adhesive. In this embodiment, "reactivation" means that the adhesive is heated to a point where it melts from its solidified state and once again become sticky to the touch. It is at this point that the fitment is prepared to be secured to the package.

At another point on the applicator machine the packages are prepared for introduction 36 to the machine. In this embodiment, the packages have been prefilled and sealed. However, packages not yet filled could also be used with the present invention. The packages are conveyed 38 into a package infeed station on the applicator machine. The packages are conveyed along a track preferably having guide rails to a joining station on the applicator machine. It is at the joining station where the fitment is actually placed 40 on the package. After the adhesive on the fitments have passed through the heating station along the fitment conveyor path and the package fitment attachment surfaces have been preheated, means associated with the joining station grasp the fitments and place them on predetermined package locations. The fitments then begin to cool 42, bonding the fitment to the package through solidification of the adhensive. Once the fitment has been secured to the package, the package leaves 44 the joining station by a conveyor and moves to an exit station of the applicator machine in preparation for shipping 46.

Referring now to Figures 2 and 3, the entire fitment applicator machine 50 is shown. The main components of the machine 50 are: a main turret assembly 52; a package infeed star wheel assembly 54; a package discharge star wheel assembly 56; a frame assembly 58; a main drive assembly 60; a fitment introduction assembly 62; a conveyor assembly 64; a vibratory fitment feeder 66; and a package infeed mechanism 68. The overall machine 50, with the exception of the improvements made to it, and described herein, for accomplishing the present invention, is a turret style "capping" machine such as manufactured by New Jersey Machine Company in Fairfield, New Jersey. The applicator machine 50 is designed to run at constant motion and preferably operating at a speed of 100 packages per minute or more.

The packages 70 are fed into the package infeed station 68 and conveyed to an infeed star wheel 72 which gathers a package 70 and transfers it to the applicator rotating turret wheel 74. At the other end of the machine the fitments 80 are loaded into the feed hopper 82 and pass through to a vibratory bowl 84 where they are automatically sorted and transported to the fitment introduction station conveyor 86. The fitments 80 are^* then indexed over a heating station 88 where the preapplied hot-melt adhesive is reactivated. The fitments 80 then approach the rotating turret wheel 74 via the heating station conveyor 88 where they are grasped by pick-up devices 90 mounted on rotating turret 74. The pick-up devices 90 transfer the fitments 80 to the packages 70 where the fitments are then held in place by the pick-up devices on the packages until the fitments are fully adhered. The packages 70 with the fitments 80 secured thereto are then transferred from the main turret wheel 74 to the discharge star wheel 92. The discharge star wheel 92 transfers the packages to an exit conveyor 94 which conveys the packages 70 to an exit station 100.

Referring now to Figures 4 and 5, there is shown in greater detail the main turret wheel 74 and star wheel assemblies 54 and 56. Also shown are the infeed conveyor 69, the exit conveyor 94, the fitment conveyor 86, the heating station conveyor 88, and the pick-up devices 90 for grasping the fitments 80 to place them on packages 70. The main drive assembly 60 actuates the turret wheel main shaft 76 by a main gear box. The gear box is driven by a variable speed DC motor. The infeed star wheel 72 and discharge star wheel 92 may be gear driven by the main gear mounted on turret wheel main shaft 76. The infeed and outfeed star wheels 72 and 92 are mechanically synchronized with the main turret 74. The main turret 74 has pockets 78 for gathering individual packages 70. Each of the star wheels 72 and 92 are designed with multiple faces 73 and 93 for gathering and transferring individual packages 70 to and from turret wheel 74 as the wheels 72, 74 and 92 all turn on their respective axes. The main drive assembly 60 may be enclosed below deck 51 under turret wheel 74.

A number of fitment pick-up devices 90 are mounted on a head support assembly 91 and turn with the turret wheel 74. Each fitment 80 is mechanically registered within a pick-up head 96 as each fitment 80 leaves heating station conveyor 88 and is held in place by vacuum. The vacuum supply 98 is rotary cam controlled via turret center shaft 76. Figure 6 shows fitment pick-up device 90 in greater detail. Several different means could be used to attach fitment pick-up devices 90 to the turret wheel assembly 91. In this embodiment, plate 102 is secured to a vertical slide 104 of turret assembly 52. Two shafts 106 and 108 are mounted to plate 102 and are of a length which enables a slideable support member 110 to be adjusted to a predetermined distance away from vertical slide 104. Associated with the slideable support member 110 is the vacuum line 98 leading into member 110 and a spring loaded shaft 112 secured at one end within slideable support member 110. At the other end of spring loaded shaft 112 is the fitment pick-up head 96. As the fitments 80 are conveyed to a position near the turret wheel assembly 52, the fitments 80 are indexed into a position for pick-up by head 96 of the pick-up device 90 that is in constant turning motion on turret wheel assembly 52. A plurality of pick-up devices 90 may be mounted to turret wheel 74. As the head portion 96 of pick-up device 90 makes contact with the fitment 80 a vacuum from vacuum line 98 holds fitment 80 within head 96 until the fitment 80 is placed on package 70. The turret wheel 74 will continue to turn as package conveyor 69 transfers packages 70 through infeed star wheel 72 to momentary aligned positions under respective pick-up devices 90. The plate 102 on which the. pick-up device 90 is mounted is actuatable vertically to lower the pick-up device so that head 96 may place a fitment 80 on each package 70. As fitment 80 makes contact with package 70 the head 96 applies a downward pressure to fitment 80 through spring loaded shaft 112. This downward pressure further assists in the bonding of the reactivated fitment adhesive to package 70 resulting in a leak-proof connection between fitment 80 and package 70. In Figure 7, a completed package 70 is shown having a^* fitment 80 secured thereto. It should be recognized that fitment 80 may be placed at any position on package 70 by making adjustments in the position of the pick-up device assembly 90 and/or adjusting the orientation of package 70 on package conveyor 69.

Fitments 80 are placed in a feed hopper 82 as shown in Figure 3, with a capacity to hold many fitments at once. The hopper 82 automatically feeds random fitments 80 into vibrating hopper 84. The vibrating hopper 84 is fitted with a mechanical transfer device 85 to feed fitments 80 into a fitment introduction station conveyor 86. The conveyor 86 is a mechanical/pnuematic device that transports fitments 80 along water cooled guide rails 87. Conveyor 86 is height adjustable to accommodate all package sizes. Heating station conveyor 88 is fitted with mechanical retraction device 89 in order to allow fitments 80 to be removed from conveyor 88 by pick-up device heads 96. Cooling water is taken from the package conveyor 69 water spray supply prior to being sprayed on conveyor 88.

As shown in Figures 9, 10 and 11, heating station conveyor 88 is added to machine 50 to reactivate the adhesive applied to the base of each fitment 80. The adhesive is reactivated by means of heater station conveyor 88 that includes a radiant pre-heater block 200 fitted with cartridge heaters 184, a final heating stage consisting of convection heater 180, and preferrably having a specially designed heating head 126 with a pattern 202 to give a dimpled effect to the hot melt adhesive. Heated air is generated by heating element 182 and conveyed by a fan which in one embodiment of the invention is a 3000 watts, 240V device. The heater 182 may be contained in a splash-proof housing and manifold 180 may have a water drain to prevent water from entering the heating element. The heating station conveyor assembly 88 may also be height adjusted to accommodate different package sizes. Hot air convection heat and infrared block temperatures are controlled by temperature controllers and thermocouples that may be equipped with quick disconnects for ease of replacement.

An air cylinder 186 is provided with the air heater assembly 182. The air cylinder 186 may be Model DGS-16-25-P-A by Festo. A cam follower 188 works in conjunction with the air cylinder 186. Idler sprocket 190 on idler shaft 192 guides the chain 193 that actuates the conveyor 88. Air cylinders 194 and 196 also serve in the movement of the fitment through the heating station. Heater support 198 and pre-heater block support 210 provide stability to the assembly. Heater pivot 204, heater rear pivot shaft 206 and heater rear pivot block 208 allow relative movement of the heater assembly. The heating station conveyor assembly 88 includes the infeed support cover 212 and infeed block 214. Gate guide 216, walking pivot 218, and pivot shaft 220 function to transfer the fitments to the point where .they are picked up by the fitment pick-up devices 90. Rear guide for fitments 222, and front guide for fitments 224, having water tunnels 226 therein for coding, guide the fitments. Adjusting shaft 228 actuates the adjusting mechanisms of the assembly.

A fitment stopper 230 with a fitment stopper pad 232 is provided at the point where the fitments 80 enter the heating station conveyor 88 from the fitment introduction station conveyor 86. A walking frame 234 is provided for transferring the fitments 80 along the heating station conveyor assembly 88. A walking block 236 and adjustment beam 238 provide actuation means to the conveyor 88. The conveyor 88 has associated with it a plurality of walking fingers 240 having walking pins 242 secured thereto for guiding the fitments 80 along the conveyor. Within the walking block 236 there is a walking beam shaft 244 and a sprocket idler bracket 246.

Referring now to Figure 8, a unique package infeed station 68 is shown. Two conveyors 69 and 140 are shown with one of the conveyors being conveyor 69 to the applicator machine 50. The other conveyor 140 is loaded with packages 70 in preparation for automatically aligning and presenting packages 70 in a timely manner to the applicator machine conveyor 69. This is accomplished by a separate package conveying mechanism 142. This mechanism 142 consists of a plurality of push members 144 which revolve around a predefined path 146. As each push member 144 approaches the preload conveyor 140 it will make contact with side 148 of a package 70. As the push member 144 continues to move around its predetermined path 146, due to the orientation of path 146, the push member 144 will push package 70 over onto applicator machine conveyor 69. Once on the applicator machine conveyor 69 a package 70 is spaced apart from other packages on the conveyor by arms 150 extending from a belt 152 which is driven by two wheels 154 and 156 or pulleys. Each arm 150 will contact the rear edge 158 of package 70 due to belt 152 moving at a faster speed than the application machine conveyor 69. Each package 70 will be properly spaced apart from those packages preceding and following it due to the positioning established by the conveyor arms 150 on belt 152.

The applicator machine 50 may also be equipped with a programmed control system to indicate fault conditions. Various malfunctions may be indicated, such as: vibrating track empty, feeder hopper empty, hopper low, fitment jam, low temperature, low air pressure, downstream jam, etc. The machine may be fitted with a controlled stop button and an emergency stop. A model number S5 102U 24VDC programmable controller by Siemens was used in one preferred embodiment.

It is thought that the apparatus and method of the present invention and many of their attendant advantages will be understood from the foregoing description. It will be apparent that various changes may be made in the form and construction of the components and steps thereof without departing from the spirit and scope of the invention or sacrificing all of its material advantages. The invention hereinbefore described is merely a preferred or exemplary embodiment thereof.

Claims

WHAT IS CLAIMED IS:

1. A method for applying a fitment to a package, said package to contain pourable contents, said contents to be pourable through an opening in said fitment, said method comprising the steps of: applying an adhesive to a base portion of said fitment, said base being a surface of said fitment that will be in contact with said package; allowing said adhesive to solidify; loading said fitment with solidified adhesive into a fitment introduction station of an applicator machine; filling said package with said pourable contents prior to loading said package into a package infeed station of said applicator machine; loading said package into said package infeed station of said applicator machine; reactivating said adhesive on said fitment within a heating station on said applicator machine;

^* aligning said fitment so that said fitment will be in a predetermined position to be secured to said package; grasping said fitment with an automated fitment pick-up device; placing said fitment on a predetermined location on said package at a joining station of said applicator machine, such that said base portion of said fitment having said reactivated adhesive thereon is secured to said predetermined location on said package; holding said fitment onto said package prior to said releasing by applying pressure on said fitment through said pick-up device; and releasing said fitment automatically from said pick-up device after said pick-up device has placed said fitment on said package.

2. The method of claim 1, further comprising: sealing said package containing said pourable contents so that said contents will not leak from said package; and securing said fitment to said package in a leakproof manner so as not to create any leak in said package.

3. The method of claim 1, wherein said reactivating said adhesive is accomplished by directing convection heat at said fitment.

4. The method of claim 1, wherein said reactivating said adhesive is accomplished by said fitment being transferred past a radiant preheater block.

5. The method of claim 1, wherein said adhesive is a thermoplastic resin or glue.

6. The method of claim 1-, wherein said step of placing said fitment on said package is continuous, in that said applicator machine is in constant motion and a plurality of said fitments can be secured to a plurality of said packages in non-stop fashion by said packages being conveyed in an orderly arrangement from said package infeed station to said joining station and by said fitments being conveyed in an orderly arrangement from said fitment introduction station to said joining station, securing said fitments to respective said packages and conveying said packages, having secured fitments thereon, in an orderly arrangement from said joining station to an exit station on said applicator machine.

7. The method of claim 1, wherein said grasping and said releasing of said fitment is accomplished by initiating and terminating respectively, a vacuum applied through said pick-up device.

8. The method of claim 1, wherein said package is an aseptic paperboard laminate structure.

9. The method of claim 1, wherein said fitment is plastic.

10. An apparatus for applying a fitment to a package, said package to contain pourable contents, said apparatus comprising: means for conveying said fitment from a fitment introduction station of said apparatus to a joining station of said apparatus; means for reactivating an adhesive previously applied to said fitment; means for conveying said package from a package infeed station of said apparatus to said joining station; means for grasping said fitment from said means for conveying said fitment to place said fitment onto said package; means for placing said fitment onto a predetermined location on said package; means for aligning said fitment within said means for conveying said fitment so that said fitment is orientated properly to be secured to said predetermined location on said package; and means for conveying said package having said fitment placed thereon to an exit station of said apparatus.

11. The apparatus of claim 10, further comprising: means for continuously and automatically securing a plurality of said fitments onto respective said packages by non-stop operation of said apparatus.

12. The apparatus of claim 10, wherein said means for reactivating an adhesive includes a radiant preheater block.

13. The apparatus of claim 10, wherein said means for grasping said fitment includes a spring loaded pick-up device which holds said fitment by a vacuum within the head portion of said device.

• 14. The apparatus of claim 10, wherein said means for aligning said fitment includes a movable track with guide rails.