Background This invention relates to an apparatus and a method for applying carriers to containers in a packaging operation and, more particularly, to an apparatus and method for applying carriers to containers for carrying the container by its neck.

Containers, and in particular liquid containers, such as glass or plastic bottles and jars, in which carbonated beverages, juices, fruit drinks and the like are packaged, can weigh a substantial amount. For example, a filled one gallon milk jug weighs approximately 8.3 pounds. When shoppers purchase such gallon containers, they generally must use a handle to carry the container. Sometimes a handle which is integral with the container is provided. Alternatively, a separate carrier is secured to the container. Carriers which enable liquid containers to be carried by their necks are well known. However, containers such as bottles or jugs having annular flanges in their necks, sometimes referred to as "stop rings", have presented a particularly troublesome problem for accommodating container carriers. In particular, the neck-engaging rings of the carriers are required to be resilient enough to slip over the larger diameter of the neck flange while at the same time having a sufficiently small diameter to fit snugly against the container neck immediately below the flange and having sufficient tensile strength to support the weight of the container. Radial slots are sometimes provided spaced about the circumference of the rings to allow the rings to slip over the flange. Moreover, conventional machinery for the application of such container carriers in a manufacturing environment suffers from inefficiency and inaccuracy, resulting in damage to both carriers and containers, which consequently leads to lost productivity.

For the foregoing reasons, there is a need for an apparatus and method for efficiently and accurately applying carriers to containers. Ideally, the new carrier applicator apparatus and method should allow for the automatic, accurate application of the carriers to liquid containers in a packaging operation. The overall operation of the apparatus should minimize damage to both carriers and containers.

Summary

According to the present invention, an apparatus is provided for use in installing a carrier on a container including a neck, the container carrier including a collar defining an opening for receiving the neck of the container. The container carrier installation apparatus comprises a frame including a mounting plate. An opening assembly including a reciprocating conical punch is mounted to the mounting plate. A support assembly includes a reciprocating die comprising a plurality of arcuate elongated members resiliently held together for defining a tube for receiving the punch. The tube has a diameter larger than the diameter of the opening in the carrier. The support assembly is mounted to the mounting plate so that the punch and the die reciprocate along the same axis. Means are provided for positioning the carrier between the punch and the die so that the center of the opening in the carrier is in alignment with the axis of reciprocation of the punch and the die. The carrier positioning means is adapted to provide lateral support to the carrier. The punch reciprocates between a first position spaced from the carrier positioning means to a second position through the opening in the carrier and into the tube defined by the elongated members of the die. The die also reciprocates between a first position spaced from the carrier positioning means to a second position adjacent the carrier for receiving the punch and supporting the carrier. The elongated members of the die pivot outwardly along the surface of the punch as the punch advances through the carrier and into the die for supporting the carrier on the punch as the punch expands the opening of the carrier.

Brief Description of the Drawings For a more complete understanding of this invention reference should now be had to the embodiments illustrated in greater detail in the accompanying drawings and described below, hi the drawings:

FIG. 1 is a front perspective view of an embodiment of an apparatus for applying carriers to containers according to the present invention. FIG. 2 is a front perspective view of the carrier applicator apparatus shown in

FIG. 1 with the frame unit and container conveyor system removed.

FIG. 3 is a front perspective view of the carrier applicator apparatus as shown in FIG. 2.

FIG. 4 is a front elevation view of the carrier applicator apparatus as shown in

FIG. 2.

FIG. 5 is a rear perspective view of the carrier applicator apparatus opposite to the view shown in FIG. 2. FIG. 6 is another rear perspective view of the carrier applicator apparatus as shown in FIG. 2.

FIG. 7 is yet another rear perspective view of the carrier applicator apparatus as shown in FIG. 2.

FIG. 8 is a perspective exploded view of a cartridge of carriers and one of the carriers for applying to containers using the carrier applicator apparatus according to the present invention.

FIG. 9 is a perspective view of a carrier for applying to containers using the carrier applicator apparatus according to the present invention after the carrier opening has been expanded. FIG. 10 is a close-up view of the carrier applicator apparatus as shown in FIG. 4 showing a spindle transporting carriers and means for opening the carriers and installing the carriers on a container.

FIG. 11 is an exploded perspective view of an embodiment of an opening cone assembly according to the present invention. FIG. 12 is an exploded perspective view of an embodiment of a cone die assembly according to the present invention.

FIG. 13 is a close-up view of the carrier applicator apparatus as shown in FIG. 10 showing a cone of an opening cone assembly advanced toward the spindle from the position in FIG. 5. FIG. 14 is a close-up view of the carrier applicator apparatus as shown in FIG.

13 showing the cone advanced through the carrier on the spindle and into a cone die.

FIG. 15 is a close-up view of the carrier applicator apparatus as shown in FIG.

13 showing the cone advanced toward the spindle and a longitudinal cross-section of the cone die in the position shown in FIG. 10. FIG. 16 is a close-up view of the carrier applicator apparatus as shown in FIG.

14 showing the cone advanced through the carrier on the spindle and into the cone die.

FIG. 17 is a close-up view of the cone, carrier and a longitudinal cross-section of the cone die as the cone initially engages the carrier and is advanced toward the cone die.

FIG. 18 is a close-up view of the cone, carrier and the cone die as shown in FIG. 17 with the cone advanced through the carrier into the cone die and the opening in the carrier enlarged around the cone.

FIG. 19 is a front perspective view of the carrier applicator apparatus shown in FIG. 1 with the upper portion of the frame unit removed and containers on the container conveyor system showing the apparatus in an on-line position. FIG. 20 is a front perspective view of the carrier applicator apparatus as shown in FIG. 19 showing the apparatus in an off-line position.

Description

Certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. For example, words such as "upper," "lower," "left," "right," "horizontal," "vertical," "upward," and "downward" merely describe the configuration shown in the FIGs. Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise. The term "air cylinder" as used herein, refers to single or double-acting fluid driven pneumatic cylinders. The connection of the air cylinder to the parts the air cylinder moves is generally conventional in nature and will not be described in further detail other than to point out that the appropriate arrangements can be made without undue experimentation in the apparatus and method of the present invention. It is understood that other devices, such as solenoids, could be used in the present invention.

The term "carrier" as used herein, refers to any carrying means that, in combination with a container, allows for the transport of the container.

The term "container" as used herein, refers to any container including a neck portion adapted for receiving a carrier having a container-engaging opening. The container may hold a liquid, for example, beverages and the like.

Referring now to the drawings, wherein like reference numerals designate corresponding or similar elements throughout the various drawings, an embodiment of an apparatus for applying carriers to containers according to the present invention is

shown in FIG. 1 and generally designated at 30. The carrier applicator apparatus is a continuous motion machine which functions to automatically grip, bend and open an appropriately positioned carrier and install the carrier onto a container.

The carrier applicator apparatus 30 comprises a structural frame unit 32 for providing support and strength to the apparatus 30. The frame unit 32 includes front vertical leg members 34 and rear vertical leg members 36. The leg members 34, 36 support a lower bracket assembly 38 and an upper bracket assembly 40. The lower bracket assembly 38 comprises two parallel sets of four horizontal strut members 42 joined at their ends to the leg members 34, 36. The upper bracket assembly 40 includes a pair of spaced strut members 44 extending horizontally from each of the rear upright leg members 36. A rectangular frame 46 is vertically mounted to the front ends of the strut members 44. Opposed intermediate vertical support members 48 extend between the upper strut members 42 of the lower bracket assembly 38 and the lower strut members 44 of the upper bracket assembly 40. The entire apparatus 30 is mounted on threaded leveling feet 50 received in the bottoms of the upright leg members 34, 36. As shown in FIG. 1, the lower bracket assembly 38, the upper bracket assembly 40, and the vertical support members 48 define a space for receiving a conveyor system 52.

The lower strut members 44 of the upper bracket assembly 40 each support two spaced horizontal linear shaft mounts 54 located in series with each other between the rear upright leg members 36 and the front frame 46. Opposed parallel cylindrical linear shafts 56 are mounted on the shaft mounts 54. Two spaced threaded mount supports 58 extend upwardly from each of the linear shafts 56. A mounting plate 60 is provided having openings for receiving the mount supports 58. The mount supports 58 accept nuts 62 for securely anchoring the mounting plate 60 to the linear shafts 56. As will be described more fully below, this arrangement comprises means for moving the mounting plate 60 relative to the frame unit 32 allowing the carrier applicator to be taken off-line if there is, for instance, no containers, or a need to produce containers without carriers.

A cross member 64 spans the upper ends of the rear leg members 36 for defining a rear control area. A control box 66 is secured to the rear leg members 36 and cross member 64.

Each of the sub-systems of the carrier applicator apparatus 30 according to the present invention is described in more detail below. A series of carrier positions

are described and shown in the FIGs. Each of the various carrier positions are indicative of operations of the sub-systems of the apparatus 30. In operation, a carrier would be present at each illustrated location at any one instance. Electrical lines and fluid lines are not shown in the FIGs. to avoid unnecessary complication. The routing and number of such lines is apparent from this description.

An apparatus for dispensing carriers to be applied to containers is supported above the mounting plate 60 and is generally designated at 80. Referring to FIGs. 2-7, the carrier dispensing apparatus comprises a conveyor system including an endless conveyor belt 84 and a motor 86. The conveyor belt 84 is supported on two rotating cylinders 83, 85. The motor 86 rotates the cylinder 85 at one end of the conveyor belt 84 for moving the conveyor belt. The conveyor belt 84 is disposed between opposed vertical sidewalls 88, which define a magazine sized for loading carriers in cartridge form 114. The sidewalls 88 provide support for the cartridges 114 as the cartridges move along the conveyor belt 84, as indicated by the directional arrow in FIGs. 2-5. A container carrier suitable for use in the present invention is shown in FIGs. 8 and 9 and described in pending International Patent Application No. PCT/US04/15279, entitled "Container Carrier" and filed May 13, 2004, the contents of which are hereby incorporated by reference. The container carrier, generally designated at 90, comprises a thin substantially planar flexible platform 92. The inner region of the platform 92 includes a container-engaging portion 94 and a handle portion 96. The container- engaging portion 94 comprises a collar 98 which defines a circular opening 100 through the platform 92. The handle portion 96 of the container carrier 90 is generally U- shaped, comprising a base 102 and two handle arms 103. The ends of the base 102 are integral with the proximal ends of each of the handle arms 103. The distal end of each handle arm 103 is integral with the collar 98 at opposed points on the collar 98. As best seen in FIG. 8. the base 102 of the handle portion 96 includes a flange 104 extending inwardly from the base 102. The width of the flange 104 is about twice the width of the base 102. The flange 104 is scored by two parallel lines 106, 108. Both score lines 106, 108 traverse the width of the flange 104. The first score line 106 is formed at the boundary of the base 102 and the flange 104. The second score line 108 is formed along the central longitudinal axis of the flange 104. The inner periphery of the container-engaging portion 94 and the handle portion 96 define a second opening 110. Preferably, the base 102 is sized so that the opening 110 is wide enough to provide

finger access to the opening 110. Opposed parallel elliptical slots 112 are formed at the distal ends of the handle arms 103 for facilitating the dispensing of the carrier 10, as will be described below.

The carrier 90 maybe composed of any suitable synthetic polymer that is tear resistant, relatively rigid, flexible, capable of temporary deformation and relatively easy to perforate, including without limitation, polycarbonate, polyethylene (PET), high density polyethylene (HDPE), polypropylene, nylon polymers (i.e., polyamides) and the like, and blends thereof. It is understood that the scope of the invention is not intended to be limited by the materials listed here, but may be carried out using any material which allows the construction and operation of the apparatus and method described herein.

Individual carriers 90 are arranged in a cartridge 114 of stacked carriers connected by a fusion bond between individual carriers. This arrangement facilitates shipment and loading of the carriers 90. The individual carriers 90 are readily sheared from the cartridge 114 for dispensing. The cartridge form 114 of the carriers 90 for use in the present invention, and methods of dispensing the carriers 90 from the cartridge 114, have been previously described in U.S. Patent No. 4,662, 974, which issued May 5, 1987; U.S. Patent No. 4,811,861, which issued March 14, 1989; U.S. Patent No. 4,854,931, which issued August 8, 1989; U.S. Patent No. 4,946,536, which issued August 7, 1990; U.S. Patent No. 5,222,931, which issued June 29, 1993; and U.S. Patent No. 5,437,594, which issued August 1, 1995, the contents of all of which are hereby incorporated by reference.

Referring again to FIGs. 2-7, a reciprocating cartridge shuttle assembly, including a feed hopper 120 and a pneumatic shuttle 124, is mounted adjacent the motor 86 at the one end of the conveyor belt 84. The feed hopper 120 includes a stop plate

126 mounted to the shuttle 124 transversely to the conveyor belt 84. The stop plate 126 is the furthest point of advancement of the cartridges 114 on the conveyor belt 84. A push plate 128 is angularly mounted to the stop plate 126. The stop plate 126 and push plate 128 together define a hopper area. The shuttle 124 is slidably mounted on bars 122 held between end plates 123, which function as the limits of movement of the shuttle 124.

In operation, a pressurized gas is supplied to an air cylinder (not shown) for reciprocating the shuttle 124 between a first "home" position (shown in the FIGs.)

where the feed hopper 120 is at the end of the conveyor belt 84 for receiving cartridges 114 and a load position. When a cartridge 114 is in the hopper area, extension of the shuttle 124 from the home position to the load position causes the stop plate 126 and push plate 128 to propel the cartridge 114 from the conveyor belt 84 until the cartridge 114 drops into a feed stack 130. Angled guide rods 132 guide the cartridge 114 into position in the feed stack 130. Once in the feed stack 130, motorized nip wheels 134 provide a downward force on the cartridge 114. As best seen in FIG. 7, when the shuttle 124 is in the load position, a second stop plate 136 angularly mounted to the push plate 128 holds the cartridges 114 from advancing on the conveyor belt 84. An upper optical sensor 138 and a lower optical sensor 140 are positioned adjacent to the upper end of the feed stack 130 for signaling the air cylinder to move the shuttle 124. The upper sensor 138 senses the cartridge 114 as the cartridge drops into the feed stack 130. Once in the feed stack 130, the upper sensor 138 no longer senses the cartridge 114 and signals the air cylinder to return the shuttle 124 to the home position. The lower sensor 140 senses the cartridge 114 in the feed stack 130. When the lower sensor 140 detects that a cartridge 114 in the feed stack 130 has been depleted and determines that a new cartridge 114 is therefore needed, the sensor 140 signals the air cylinder to actuate and move the shuttle 124 for loading another cartridge 114. A third sensor 142 is disposed on the support wall 88 and senses cartridges 114 on the conveyor belt 84. When the third sensor 142 no longer senses a cartridge 114 on the conveyor belt 84, the sensor 142 signals the need to add cartridges. Additional cartridges are illustrated as replacements in FIG. 1 and may be added when the sensor 142 does not detect a cartridge 114 on the conveyor belt 84.

Referring to FIGs. 2-6, a spindle assembly is provided below the feed stack 130 for dispensing one carrier 90 at a time from the bottom of the cartridge 114 for installation on a container. The spindle assembly comprises an indexing spindle 152 including spaced parallel inner and outer wheels 154. Opposed feed gates 157 are positioned above the wheels 154 adjacent the bottom of the cartridge 114 in the direction of rotation of the spindle 152. Entrance guides 158 are secured adjacent each of the feed gates 157. Spaced parallel inner and outer guide plates 160 are positioned below the entrance guides 158 adjacent the spindle 152. Only the inner guide plate 160 is shown in the FIGs. With the outer guide plate removed, an upper rectangular spacer 162 and a lower cylindrical spacer 163 for connecting the guide plates 160 are visible.

As seen in FIGs. 1 and 10, the guide plates 160 are positioned in respective slots in the mounting plate 60 such that a portion of each guide plate 160 is above the mounting plate 60 and a portion is below the mounting plate 60. The inner surfaces of the guide plates 160 are arcuate and correspond to the outer circumference of the spindle 152. In this configuration, the guide plates 160 and the spindle 152 define a narrow arcuate channel. The guide plates 160 are slidably suspended from the upper spacer 162, which rests on the upper surface of the mounting plate 60, and are movable relative to the mounting plate 60 toward and away from the spindle 152 within the limits defined by a bridge 166 secured over the upper spacer 162. A locking mechanism 164 is provided for securing the position of the guide plates 160. This arrangement allows for the guide plates to be quickly and easily moved away from the spindle 152 for maintenance, such as to clear a jam. As seen in FIG. 5, opposed shear dogs 156 are secured on the periphery of each wheel 154 and spaced about 90° apart along the circumference of the wheels 154. The shear dogs 156 extend beyond the periphery of the wheels 154. As the spindle 152 rotates past the cartridge 114 in the feed stack 130, an opposed pair of shear dogs 156 enters the slots 112 in the carrier 90 and shear the carrier from the bottom of the cartridge 114. The feed gates 157 are positioned such that only one carrier 90 can pass beneath the feed gates 157 thereby insuring the detachment of only one carrier 90 from the cartridge 114. As the spindle 152 continues to rotate, the disengaged carrier 90 passes the entrance guides 158, which push the carrier 90 against the spindle 152 as the carrier enters the channel defined between the spindle 152 and the guide plates 160. The guide plates 160 maintain the alignment of the carrier 90 in a predetermined position on the shear dogs 156 and against the spindle 152. The spindle 152 advances the carrier to a predetermined carrier opening position, which is designated at 168.

As shown in FIGs. 1-7 and 10, a carrier opening assembly is mounted below the mounting plate 60 adjacent to the spindle 152. The carrier opening assembly comprises an opening cone assembly and a cone die assembly. The opening cone assembly for use according to the present invention is shown in FIG. 11 and generally designated at 170. The opening cone assembly 170 includes a truncated opening cone 172, a cam 173, a cam guide 174, a reducer gear box 176 and a drive crank 178 including a cam roller 180. The cam 173 has a vertical slot 181 for receiving the cam roller 180. A tool holder 182 is secured to the front end of the cam 173. The cone 172 is mounted to the

tool holder 182 via a threaded stud 184 which is pinned to the tool holder 182. The cam 173 fits against the cam guide 174. The cam guide 174 includes a fixed guide portion 175 and a slide portion 177, which is slidably received in the guide portion 175. Two retainers 179 are used to secure the cam 173 to the slide portion 177. The retainers 179 fit into corresponding longitudinally spaced openings 183 in the cam 173. The retainers receive fasteners (not shown) which extend through aligned openings 185 in the slide portion 177 of the cam guide 174 for securing the cam 173 to the slide portion 177. A key 188 fixed in a horizontal slot 190 in the side of the cam 173 is received in a longitudinal groove 186 in the slide portion 177, which further secures the position of the cam 173 relative to the slide portion 177. The crank 178 and roller cam 180 provide a reciprocating drive means such that rotation of the crank 178 will cause linear reciprocation of the cone 172 and cam 173. A guide bracket 196 and a gear box bracket 198 are provided for mounting the cam guide 174 and the gear box 176, respectively, to the mounting plate 60. The opening cone assembly 170 also includes a handle punch assembly.

Referring to FIGs. 10 and 11, the handle punch assembly comprises a handle punch 192 and a handle clamp 194. The handle punch 192 is a flat bar including threaded posts 202 extending from the upper surface. The handle punch 192 is fastened to the top of the shoulder on the tool holder 182 and extends outwardly from the tool holder 182 substantially parallel to the cone 172. The handle clamp 194 is also a flat bar having two parallel longitudinal slots 200 which receive the threaded posts 202 on the upper surface of the handle punch 192. A thin plate 204 is fastened to the posts 202 for slidably sandwiching the handle clamp 194 between the handle punch 192 and the plate 204. A spring post 206 extends from the front end of the cam 173 and through a hole in the tool holder 182 behind the handle clamp 194. The spring post 206 mounts a spring 208 which biases the handle clamp 194 outwardly of the cam 173.

The cone die assembly for use according to the present invention is shown in FIG. 12 and generally designated at 215. The cone die assembly 215 comprises a cone die 220, including a plurality of fingers 224, and a cylindrical support member 222. The support member 222 has radial flanges 226 at each end. Each of the fingers 224 has inner transverse grooves 228 spaced from the proximal ends of the fingers 224. The fingers 224 fit around the support member 222 such that the grooves 228 receive the outer flange 226 of the support member 222. Each of the fingers 224 also has outer

transverse grooves 228 spaced from the distal ends of the fingers 224. A circular spring 231 fits in the outer transverse grooves 229 on the periphery of the fingers 224 thus surrounding the distal end of the cone die 220. The spring 231 biases the fingers 224 together forming a tube and holding the fingers 224 on the support member 222. The spring 231 provides resistance to pivoting action of the fingers 224 on the support member 222. Preferably, the spring provides no more than about 1.5 lbs of force at full compression. The support member 222 is mounted to a base plate 230. The support member 222 and base plate 230 are bolted to an air cylinder 232 through a horizontal plate 234 and a vertical plate 236. A top plate 240 is secured to the base plate 230 and the vertical plate 236 parallel to the horizontal plate 234. A handle die 238 is mounted to the top plate 240. A slide block 242 is fastened to the top plate 240 behind the handle die 238. The slide block 242 has two longitudinal cylindrical passages 243 for receiving slide shafts 244 which are held in place at each end by shaft supports 246 fastened to the mounting plate 60. The cylinder rod of the air cylinder 232 is connected to the vertical plate 230 to provide radially reciprocating movement to the cone die 220 and the handle die 238 relative to the spindle 152. The slide block 242 and shafts 244 support the reciprocal motion of the cone die assembly 215.

An angular bracket 248 is provided for mounting the cone die assembly 215 to the mounting plate 60. When in place, the bracket 248 extends downwardly from the mounting plate 60 between the wheels 154 of the spindle 152. The cone die 220 and handle die 238 extend radially outwardly from the bracket 248 relative to the spindle 152 such that the distal ends of the cone die 220 and the handle die 238 are adjacent the periphery of the wheels 154.

The cone 172 and cone die 220 reciprocate along the same axis. As seen in FIG. 10, when a carrier 90 on the spindle 152 is in the carrier opening position 168, the axis of reciprocation of the cone 172 and the cone die 220 is further aligned with the center of the opening 100 in the collar 98 of the carrier 90.

Referring now to FIGs. 13 and 14, a carrier 90 opening cycle is caused by rotation of the crank 178 by a continuous drive motor 210 coupled to the gear box 176. As described above, this causes linear reciprocation of the cone 172 and cam 173 due to the captive engagement of the roller cam 180 within the slot 181 in the cam 173. The cam 173 reciprocates between a "home" position, which is shown in FIG. 10, and an extended "opening" position, which is shown in FIG. 14. As the cone 172 moves

toward the carrier 90 on the spindle 152, the forward end of the cone 172 passes through the carrier opening 100 and slips into the distal end of the cone die 220. As the cone 172 is advanced toward the cone die 220, the air cylinder 232 extends the cone die 220 from a position spaced from the periphery of the wheels 154 (FIG. 15) to a position adjacent the inner surface of the carrier 90 (FIG. 13). The extended position of the cone die 220 relative to the carrier 90 is shown close-up in FIG. 17. As seen in FIG. 17, a slight gap is maintained between the ends of the fingers 224 of the cone die 220 and the inner surface of the carrier 90 which is held on the spindle 152. This gap is allows the carrier 90 to flex inwardly before expansion around the cone 172 in order to prevent splitting of the carrier 90. Preferably, the gap is at least about 1/8 inches. The maximum possible size of the gap depends on the material and thickness of the carrier 90. If the gap is too great, the edges of the carrier 90 where held by the shear dogs 156 are stretched.

After the initial inward flex of the carrier 90, the ends of the fingers 224 engage the inner surface of the carrier 90 for providing lateral support to the carrier 90 for penetration by the cone 172. The inner edge of the end surfaces of the fingers 224 of the cone die 220 are chamfered. This configuration permits the fingers 224 to fully support the carrier 90 while ensuring that the cone 172 will extend through the carrier opening 100 without "coining" of the carrier 90 (FIG. 18). Referring now to FIGs. 14 and 16, the cone 172 extends through the carrier 90 a predetermined distance with sufficient force to cause the beveled body of the cone 172 to expand the carrier opening 100. The extension distance is chosen such that the diameter of the expanded carrier opening 100 is larger than the diameter of the stop ring on the container to which the carrier 90 will be applied, as will be described below. The fingers 224 pivot relative to the cylindrical support 222 as the fingers 224 advance along the cone 172 for supporting the carrier 90. At the same time, the handle clamp 194 pins the base 102 of the handle portion 96 against the handle die 238. Advancement of the cam 173 to the fully extended position causes the handle punch 192 to engage the flange 104 of the handle portion 96 of the carrier 90 thereby driving the flange 104 inwardly and causing the flange to bend at the score lines 106, 108.

FIG. 9 shows a carrier 90 after the opening process showing the collar 98 and flange 104 reshaped so as to both extend above the plane of the platform 92. The collar

98 is in the shape of a truncated cone. The flange 104 is bent upwardly and allows a user to more easily grasp the carrier 90 to transport a container.

Following opening of the carrier 90, opening cone 172 and cone die 220 and retract to their original "home" positions shown in FIG. 10 by operation of the crank 178 and air cylinder 232, respectively. It is understood that the arrangement does not have to be horizontal and that the position may vary.

The spindle 152 then advances the carrier 90 to a predetermined carrier installation position generally designated at 255 in FIG. 13. In the carrier installation position 255, the carrier 90 is aligned with the top of a container 250. An applicator assembly is provided for installing the carrier 90 on the container 250. The applicator assembly for use according to the present invention is shown in FIG. 12 and generally designated at 260. The applicator assembly 260 comprises an applicator head 262 and an air cylinder 264. The applicator head 262 is cup-shaped and has a selected diameter slightly larger than the diameter of the expanded carrier opening 100. The applicator air cylinder 264 is mounted to the same bracket 248 as the cone mandrel between the wheels 154 of the spindle 152. The cylinder rod is connected to the applicator head 262 to provide radially reciprocating movement to the applicator head relative to the spindle 152. As seen in the FIG. 10, when the spindle 152 is in the carrier installation position, the axis of the applicator head 262 is aligned with respect to the opening 100 in the carrier 90 and the top of the container 250.

Referring now to FIGs. 13 and 14, for installing the carrier 90, the applicator air cylinder 264 is actuated extending the applicator head 262 outwardly toward the carrier 90 and the container 250 from a "home" position, which is shown in FIG. 13, and an extended position, which is shown in FIG. 14. As the applicator head 262 extends, the head 262 first engages around the opening 100 of the carrier 90 for driving the carrier 90 off the shear dogs 156. Because the inner diameter of the applicator head 262 is larger than the expanded carrier opening 100, the applicator head 262 makes complete contact on the inner surface of the carrier 90. The applicator head 262 continues to extend outwardly of the spindle 152 and over the top of the container 250. Because the collar 98 is cone-shaped, the carrier 90 centers on the top of the container as the applicator head 262 descends. The predetermined stroke length of the cylinder rod is such that the lower surface of the applicator head 262 advances to a point below the stop ring 252 on the container neck. The applicator cylinder 264 then returns the

applicator head 262 to the original position leaving the carrier 90 in position on the container 250 below the stop ring 252. Within several minutes, the opening 100 in the collar 98 of the carrier 90 returns to near original size which is smaller in diameter than the stop ring 252. The container carrier 90 is thus secured to the container 48 and will not disengage during normal use. It is understood that the arrangement does not have to be vertical as shown in the FIGs. and that the position may vary. In the present embodiment, exit guides 266 are secured on the bottom edge of the guide plates 160 adjacent the periphery of the wheels 154. The exit guides 266 are positioned close enough to the wheels 154 so as to provide some drag resistance on the carrier 90 as the spindle advances the carrier 90. This drag holds the carrier on the shear dogs 156 in the carrier installation position 255.

Means including a container delivery system are provided for positioning the containers 250 traveling on the conveyor system 52 for installation of carriers 90 to the containers 250. Referring to FIGs. 1, 19 and 20, the container delivery system comprises a bottle guide assembly, generally designated at 270, and a bottle feeder assembly. As best seen in FIG. 1, the bottle guide assembly includes spaced pairs of horizontal front guide plates 272 and rear guide plates 274. Each pair of guide plates are identically shaped and have corresponding arcuate inner surfaces. The front guide plates 272 are secured to the lower strut member 47 of the front frame 46 substantially along the length of the strut member 47. The rear guide plates 274 are removably secured to the intermediate vertical support 48 at the downstream end of the conveyor system 52.

Referring to FIGs. 2-7, the bottle feeder assembly depends from the bottom of the mounting plate 60 beneath the spindle 152. The bottle feeder assembly comprises spaced horizontal star-shaped wheels 282 mounted on a rotating shaft 284. The star- shaped wheels 282 have corresponding U-shaped openings 286.

Operation of the container delivery system is shown in FIG. 19. With the conveyor system 52 moving the containers 250 from right to left as seen in FIG. 19, a container 250 advances on the conveyor system 52 into one of the openings 286 in the star-shaped wheels 282. The wheels 282 then rotate about 90° in a clockwise direction, as seen in the FIG. 19, for positioning the container 250 directly beneath the applicator head 262 for receiving a carrier 90, as described above. Means for providing a positive stop for the star wheels 282 is shown in FIGs. 5-7. The star wheel stop means

comprises a mount 312 depending from the lower surface of the mounting plate 60, a rotary actuator 314 secured to the lower end of the mount 312, and a lever 316 and a pointed stop 318 extending from the rotary actuator 314. The rotary actuator 314 is operatively connected to the same air cylinder 264 as the applicator head 262 and functions to swing the lever 316 and stop 318 relative to the star wheels 282. Each arm of the upper star wheel 282 has a v-shaped notch 320 for receiving the stop 318. Each time the star wheels 282 rotate 90°, the rotary actuator 314 rotates the lever 316 and stop 318 away from the star wheels 282. When the star wheels 282 stop, the rotary actuator 314 rotates the lever 316 and stop 318 toward the star wheels 282 so that the stop 318 is received in the notch 320 on the adjacent arm of the upper star wheel 282 for holding the star wheels 282, and thus the container 250, in the proper position.

After installation of the carrier 90 onto the container 250, the star-shaped wheels 282 again rotate about 90° and the container 250 with the attached carrier 90 is returned to the conveyor system 52. The spindle 152 simultaneously advances 90° for positioning another carrier 90 over the next container 250, stripping another carrier 90 from the cartridge 114 in the feed stack 130, and advancing yet another carrier 90 to the carrier opening position 168. This sequence is repeated in an essentially continuous process using any timing which is deemed desirable for a particular application. For example, a cycle, defined as one complete revolution of the spindle 152, lasting about four seconds results in the application of about sixty carriers 90 to containers 250 per minute.

Preferably, the means for rotating the spindle 152, the opening cone assembly 170, and container feeder assembly 260 are operated by a common drive means. Interlinked drive means insures that proper synchronization is maintained in the continuous steps of carrier 90 dispensing, transport, opening and installation in timed relation to the container 250 stock. According to one embodiment of the present invention, the drive means is built around the drive motor 210 and an indexer 298. Referring to FIGs. 6 and 7, the drive motor 210 is shown extending upwardly from the mounting plate 60. The motor 210 is operably connected to the reducer gear box 176 directly below the motor 210. An output shaft 290 and pulley 292 extend from the rear of the gear box 176. A timing belt 294 is connected between the pulley 292 and a pulley 296 mounted to the rear of the indexer 298. The rear of the indexer 298 also mounts a right angle gear box 300 which drives a pulley and timing belt assembly 302

connected to the shaft 284 of the star wheels 282. A drive wheel (not visible) on the front of the indexer 298 connects to the spindle 152 for rotating the spindle 152. The indexer 298 is designed such that each revolution of the output shaft 290 of the gear box 176 causes a synchronous 90° rotation of the star wheels 282 and the spindle 152. The motion of the star wheels 282 and the spindle 152 is timed through the gear box 176 and crank 178 such that the opening cone assembly 170 is in the home position away from the spindle 152 every time the spindle indexes one quarter of a revolution. The reducer gear box 176 then causes the cone 172 to extend and open the carrier 90 after the spindle 152 stops and retracts before the next one quarter of a revolution. As the opening cone 172 retracts to the home position, the indexer 298 moves the star wheels 282 and the spindle 152 so that the carrier 90 with the expanded opening 100 is moved to the carrier installation position 255 as the container 250 is moved into position to receive the carrier 90.

Also mounted to the output shaft 290 are two cams 304, 306 (FIG. 7) which rotate with the output shaft 290. A pneumatic mechanical valve 308, 310 is mounted adjacent to each of the cams 304, 306. The cams 304, 306 are operatively associated with pneumatic mechanical valves 308, 310 such that the valves are actuated with each revolution of the cams. One pneumatic valve actuates the air cylinder 232 for extending the cone mandrel. The other pneumatic valve actuates the cylinder 264 for extending applicator head 262 and actuating the rotary actuator 314 of the star wheel stop means.

Although maintaining proper synchronization through interlinked drive means is preferred, other alternatives are possible, such as one or more separate drive means in conjunction with servo-control means.

The control box 66 houses appropriate equipment for the operation of the apparatus 30, including electrical and pneumatic components. The apparatus 30 may be controlled by an onboard computer or central programmable logic controller (PLC). The programming of the operation of the carrier applicator apparatus 30 is easily accomplished from the logical operation of the apparatus as described herein. The PLC controls the normal operation of the unit, including the operation of the pneumatic cylinders, pneumatic control valves, operator interface, visual displays such as LCD's, indicator lights, buttons and switches. Sensors for air pressure may also be provided. Proximity sensors selectively mounted at various points on the apparatus signal the position of the moving parts of the apparatus to the PLC for various machine functions.

The carrier applicator apparatus 30 can be taken off-line with little downtime. As described above, the mounting plate 60 is mounted on linear shafts 56 which ride in shaft mounts 54. Thus, the mounting plate 60 is movable relative to the frame unit 32. The linear shafts 56 have stops 68 at each end which establish the limits of movement of the mounting plate 60 and linear shafts 56. Locking mechanisms 70 secured to the liner shafts 56 hold the mounting plate 60 in the selected position. The off-line position is shown in FIG. 20. The off-line position requires removal of the rear guide plates 274 to clear the conveyor system 52.

The present invention has many advantages, including providing a high speed, continuous flow carrier applicator apparatus for installing a carrier on a container. The apparatus of the present invention effects a marked increase in productivity while reducing labor.

The above description is a preferred means for moving and locating a carrier for opening and installation. It is understood that other means for moving a carrier are possible. Also, the relative movement of the carrier and the opening cone assembly need not be carried out by the particular apparatus shown and described herein as any assembly which provides appropriate relative movement is possible including, for example, a chain and sprocket mechanism or a servomotor or stepper motor drive with a timing belt or ball screw linear actuator. An important feature of any suitable system, however, is the proper, accurate positioning of the cone opening and carrier applicator assemblies and the carriers prior to opening and installation, respectively. The apparatus and method of the present invention further contemplate means for opening one handle at a time for manual application onto a bottle.

It should be appreciated that a variety of various carrier configurations and aperture designs can be used with an appropriately designed carrier dispensing apparatus. Thus, while the description of the present invention is given in reference to a particular type of carrier, it is understood that variations in designs of carriers are within the present scope of the invention. Some conventional carriers may not need to have openings expanded in order to be dispensed and installed on a container according to the present invention. If desired, the conventional carriers could be modified with necessary openings to accommodate, for example, shear dogs. Thus, various conventional carriers are readily accommodated for use in the present invention.

It is also understood that the container carrier of the present invention will carry elongated containers, such as the containers shown in the FIGs. However, other types of containers or packages may be used in the present invention, such as cans, jars, jugs, spray bottles, oil containers and the like. Although the present invention has been shown and described in considerable detail with respect to only a few exemplary embodiments thereof, it should be understood by those skilled in the art that we do not intend to limit the invention to the embodiments since various modifications, omissions and additions may be made to the disclosed embodiments without materially departing from the novel teachings and advantages of the invention, particularly in light of the foregoing teachings. For example, various means for dispensing and transporting the carriers are possible according to the present invention, including manually as in a single handle apparatus. Accordingly, we intend to cover all such modifications, omission, additions and equivalents as may be included within the spirit and scope of the invention as defined by the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a crew may be equivalent structures.